WO2024059760A1

WO2024059760A1 - Post assemblies and post and beam assemblies for decking systems

Info

Publication number: WO2024059760A1
Application number: PCT/US2023/074262
Authority: WO
Inventors: Elijah R. JOHNSON; Eric Wehrli; Roger Edwin WINTER
Original assignee: The Azek Group Llc
Priority date: 2022-09-14
Filing date: 2023-09-14
Publication date: 2024-03-21
Also published as: US20240084578A1; WO2024059760A9; WO2024059760A4

Abstract

Post assemblies and post and beam assemblies for decking systems. A post assembly can include a post member and one or more post caps. The post caps can include one or more tabs that, when in an assembled configuration, are inserted into one or more slots in an interior portion of the post member.

Description

POST ASSEMBLIES AND POST AND BEAM ASSEMBLIES FOR DECKING SYSTEMS

FIELD OF THE INVENTION

[0001] The present disclosure relates to decking systems. In particular, the present disclosure relates to post assemblies and post and beam assemblies for decking systems.

BACKGROUND OF THE INVENTION

[0002] Certain conventional decking can include a support system. In such conventional decking, a support system may be designed to support a framing system.

BRIEF DESCRIPTION OF THE DRAWING

[0003] Illustrative aspects are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein:

[0004] FIG. 1 depicts an example frame structure for a decking system that includes an example post and beam assembly, in accordance with aspects hereof;

[0005] FIG. 2 depicts one perspective view of an example post and beam assembly with a rim joist coupled to the beam, in accordance with aspects hereof;

[0006] FIG. 3 depicts another perspective view of the example post and beam assembly with a rim joist coupled to the beam of FIG. 2, in accordance with aspects hereof;

[0007] FIG. 4 depicts a perspective view of an example beam clip, in accordance with aspects hereof;

[0008] FIG. 5 depicts a perspective view of an example beam bracket, in accordance with aspects hereof;

[0009] FIGS. 6A, 6B, and 6C depict an example post assembly, including a first post cap coupled to a first end of a post member and a second post cap coupled to a second end of the post member, in accordance with aspects hereof;

[0010] FIG. 7A depicts a perspective view of an example post member, in accordance with aspects hereof;

[0011] FIG. 7B depicts a top view of the post member of FIG. 7A, in accordance with aspects hereof;

[0012] FIG. 8A depicts a top view of an example post cap, in accordance with aspects hereof; [0013] FIG. 8B depicts a perspective view of the post cap of FIG. 8 A, in accordance with aspects hereof;

[0014] FIG. 8C depicts a bottom view of the post cap of FIG. 8 A, in accordance with aspects hereof;

[0015] FIG. 8D depicts another perspective view of the post cap of FIG. 8A, in accordance with aspects hereof;

[0016] FIG. 9 depicts an example post cap positioned above an example post member, in accordance with aspects hereof;

[0017] FIGS. 10 and 11 depicts perspective views of a post and beam assembly, in accordance with aspects hereof;

[0018] FIG. 12A depicts a framing member coupled to a beam, where the beam is coupled to a post assembly, in accordance with aspects hereof;

[0019] FIG. 12B depicts a close up view of the framing member coupled to the beam of FIG. 12A, particularly showing a beam clip coupled to the beam and to the framing member, in accordance with aspects hereof; and

[0020] FIG. 13 depicts another example beam coupled to a post assembly, in accordance with aspects hereof.

DESCRIPTION

[0021] Aspects herein are related to post assemblies and post and beam assemblies for decking systems.

[0022] The post assemblies and post and beam assemblies disclosed herein can include various structural features that provide increased support for the post assemblies and for the decking system overall. For instance, in various aspects, the post assembly can include one or more fastener-receiving members positioned in an interior portion of a post member that can provide structural support along the length of the post member. In the same or alternative aspects, the fastener-receiving members can be utilized to secure a post cap to an end of the post member. In various aspects, the post member can include one or more slots for receiving one or more tabs of a post cap, which, when in an assembled configuration, can further provide support along at least a portion of the length of the post member. In the same of alternative aspects, the slots may function as a guide for the proper alignment of the post cap on the post member. In one or more aspects, the beam clip discussed herein can be used to secure one or more decking framing members, e.g., a perimeter frame member and/or an inner frame member, to a beam, which can provide additional structural support, and can reduce structural loads (and/or reduce shear) on the beam and/or post assembly.

[0023] Accordingly, in one aspect, a post assembly is provided. The post assembly can include a post member. The post member can include a first end, a second end opposite the first end, and at least one sidewall. The post assembly can also include one or more post caps, where each of the one or more post caps includes a post cover and one or more tabs extending out from the post cover. When in an assembled configuration, the one or more tabs of each of the one or more post caps are positioned within one or more slots in an interior portion of the post member.

[0024] In yet another aspect, a post and beam assembly is provided. The post and beam assembly can include a post member, the post member including: a first end, a second end opposite the first end, and at least one sidewall. The post and beam assembly can further include one or more post caps, where each of the one or more post caps includes a post cover and one or more tabs extending out from the post cover, where, when in an assembled configuration, the one or more tabs of each of the one or more post caps are positioned within one or more slots in an interior portion of the post member. The post and beam assembly can further include a beam. The beam can include first and second opposing sides and opposing top and bottom sides, where, when in the assembled configuration, the beam is positioned on top of a first post cap of the one or more post caps. The post and beam assembly can also include a first beam clip coupled to the first post cap and to a first side of the beam.

[0025] As used herein, the term “about” means plus or minus 10 % of the numerical value of the number with which it is being used unless otherwise indicated or custom in the art dictates otherwise. Therefore, for example, “about 10 millimeters (mm)” includes the value 10 mm in addition to the range of 9 mm to 11 mm.

[0026] Turning to the figures, and FIG. 1 in particular, an example decking system 100 is depicted. As can be seen in the aspect depicted in FIG. 1, the decking system 100 can include framing members, e.g., perimeter frame members 200 and inner frame members 300. In the aspect depicted in FIG. 1, the decking system 100 also includes one or more post and beam assemblies 400 that can provide support to the framing members. It should be understood that the decking system 100 of FIG. 1 is provided as one example system and is not intended to include all decking components, such as a deck floor, railings, trim, and the like. In certain aspects, a deck floor, or deck boards, which can form a surface of a deck and support people, fumiture, and the like, can be positioned on top of the decking system 100 depicted in FIG. 1. Further, it should be understood that the arrangement and number of the perimeter frame members 200 and inner frame members 300 in the decking system 100 is just one example arrangement and number of frame members and is provided to highlight various features and aspects of the frame members. Alternative arrangements and numbers of perimeter frame members and inner frame members are also contemplated by the disclosure herein.

[0027] In certain aspects, the decking system 100 can also be coupled to a support structure, e.g., a side of a dwelling or other wall. In one such example aspect, a perimeter frame member, e.g., the perimeter frame member 202, can be secured to a side or edge of a dwelling or other support structure.

[0028] In various aspects, the framing members of the decking system 100 can provide enhanced support to the decking system 100 across the horizontal plane of the decking system 100, and may support a deck floor or other decking components. While in the example decking system 100 of FIG. 1, the decking system 100 is generally depicted as including a rectangular or box shape, it should be understood that other shapes of a decking system are also contemplated by the disclosure herein. For instance, in one aspect, perimeter frame members can be coupled to one another at an angle other than 90°. In the same or alternative aspects, inner frame members may be coupled to perimeter frame members and/or to other inner frame members at angles other than 90°. In certain aspects, one or more frame members may not be linear. For instance, in certain aspects, curved or non-linear frame members are also contemplated by the disclosure herein.

[0029] In certain aspects, the decking system, framing system, or post and post and beam assemblies can be formed from any type of material. In various aspects, framing members, the post member, post cap, and/or beam can include a metal material. In such aspects, any metal material that is suitable for use as framing or support systems and/or decking systems can be utilized. In certain aspects, the metal material can include aluminum. In the same or alternative aspects, the framing members, the post member, post cap, and/or beam can be formed of an extruded metal material. In one aspect, the post cap can be formed from a casting process.

[0030] FIGS. 2 and 3 provide close-up perspective views of a post and beam assembly 400. In the aspect depicted in FIGS. 2 and 3, the post and beam assembly 400 includes a post assembly 440 with a beam 410 coupled to a top of the post assembly 440 and secured thereto with a beam bracket 420 and a beam clip 430. The post and beam assembly 400, the beam bracket 420, and the beam clip 430 will be discuss further below.

[0031] The post assembly 440 will be described with reference to FIGS. 6A - 9. FIGS. 6 A - 6C depict the post assembly 440 in an assembled configuration, FIGS. 7 A and 7B depict a post member 450 of the post assembly 440, and FIGS. 8A-8D depict a post cap 480 of the post assembly 440. FIG. 9 depicts the post member 450 and the post cap 480.

[0032] As can be seen in the aspect depicted in FIGS. 6A-6C, the post assembly 440 includes a post member 450 and post caps 480 coupled to opposing ends of the post member 450. For example, as best seen in the aspect depicted in FIG. 6A, a post cap 480 is coupled to a first end 452 of the post member 450, and as depicted in FIG. 6B, another post cap, post cap 480, is coupled to a second end 454 of the post member 450. FIG. 6C depicts the post assembly 440 but with the sidewall of the post member 450 being transparent to reveal the interior portion of the post member 450 and the interactions with the post caps 480 and insertion of the post cap tabs.

[0033] As can be seen in the aspect depicted in FIG. 7A, the post member 450 includes a first end 452 and a second end 454 opposite the first end 452, and at least one sidewall 456 extending between the first end 452 and the second end 454. In the aspect depicted in FIGS. 7A and 7B, the post member 450 has a generally square cross-sectional shape. For instance, the sidewall 456 forms a first side 457, a second side 459 opposite the first side 457, a third side 458, and a fourth side 460 opposite the third side 458. It should be understood that the specific shape of the post member 450 is just one example and that other shapes of the post member are also contemplated by the disclosure herein.

[0034] As best be seen in FIG. 7B, the post member 450 includes one or more slots, e.g., slots 462 and 464 in an interior portion 451 of the post member 450. As discussed herein, such slots, e.g., slots 462 and 464, can receive at least a portion of a post cap 480, e.g., a tab or portion thereof when securing the post cap 480 to the post member 450. In the aspect depicted in FIG. 7B, the slots 462 and 464 are formed at least partly by the sidewall 456, e.g., third side 460, and slot members 463 and 465, respectively. In the aspect depicted in FIG. 7A, the slots, e.g., the slots 462 and 464, extend from the first end 452 to the second end 454 of the post member 450. In such aspects, this allows for tabs from two post caps to be secured to both ends 452 and 454 of the post member 450.

[0035] In various aspects, the interior portion 451 of the post member 450 also includes one or more fastener-receiving members, e.g. fastener-receiving members 467 and 468. The fastener-receiving members 467 and 468 are adapted for receiving a fastener, e.g., a bolt, screw, or the like, for securing a post cap 480 to the post member 450. As can be seen in the aspect depicted in FIG. 7A, the fastener-receiving members, e.g., fastener-receiving members 467 and 468, extend from the first end 452 to the second end 454 of the post member 450. In such aspects, this allows for tabs from two post caps to be secured to both ends 452 and 454 of the post member 450.

[0036] In various aspects, the slot members, e.g., slot members 463 and 465, can extend out from the fastener-receiving members, e.g. fastener-receiving members 467 and 468, as best seen in FIG. 7B. In the same or alternative aspects, the slot members, e.g., slot members 463 and 465, can be integral with the fastener-receiving members. In the aspect depicted in FIG. 7B, the post member 450 is designed so that slots are present on each side 457, 458, 459, and 460.

[0037] FIGS. 8A-8D depict various views of the post cap 480. FIG. 8A shows a top view of the post cap 480, FIG. 8B shows a top and side perspective view of the post cap 480, FIG. 8C shows a bottom view of the post cap 480, and FIG. 8D shows a bottom and side perspective view of the post cap 480. As best seen in FIGS. 8B and 8D, the post cap 480 includes a post cover 482 and one or more tabs extending out and away from the post cover 482, e.g., tabs 484 and 486. As discussed above, when the post assembly 440 is in an assembled configuration, a post cap, e.g., post cap 480, is coupled to an end of the post member 450. In such aspects, the tabs of the post cap, e.g., tabs 484 and 486, can be inserted into slots located in an interior portion of the post member 450 to provide additional structural support to the post member 450 and post cap 480. The slots may also function to provide the proper alignment of the post cap on the post member, in an aspect.

[0038] As best seen in FIGS. 8 A and 8B, the post cover 482 of the post cap 480 can include one or more through-holes. For instance, the post cap 480 includes through-holes 487,

488, 489, and 490. Fasteners can be inserted into one or more of the through-holes 487, 488,

489, and 490 to secure the post cap 480 to the post member 450, in certain aspects. In such aspects, the through-holes 487, 488, 489, and 490 can align with the fastener-receiving members of the post member 450, for receiving at least a portion of the fastener, when in an assembled configuration. As best seen in FIG. 8B, the through-holes 487, 488, 489, and 490 can be countersunk, e.g., offset from the outer surface of the post cover 482.

[0039] In various aspects, the post cover 482 can include a center slot, e.g., the center slot 491 best seen in FIGS. 8B and 8D. In certain aspects, the center slot 491 can be utilized for securing the post assembly 440 to a support, e.g., the ground or other support surface. Any convenient type of fastener can be utilized to secure the post assembly 440 to a support.

[0040] In various aspects, as discussed above, when in an assembled configuration, the tabs of the post cap are inserted into slots in the post member. FIG. 9 depicts the post cap 480 positioned above the post member 450 prior to assembly. In various aspects, the slots of the post member 450, e.g., the slots 462, 464, 470, and 472, aid in aligning the post cap 480 with the post member 450. For instance, by inserting the tab 486 into the slots 462 and 464, and by inserting the tab 484 into the slots 470 and 472, the post cap 480 will be properly aligned for fastening the post cap 480 to the post member 450, e.g., the through-holes on the post cap 480 will be aligned with the fastener-receiving members of the post member 450. FIG. 6C shows the tabs 484 and 486 of the post cap 480 positioned within the respective slots and in the interior portion of the post member 450.

[0041] FIGS. 10-12B depict various views of a post and beam assembly 400. As discussed above, the post and beam assembly 400 includes a post assembly 440 with a beam 410 coupled to a top of the post assembly 440 and secured thereto with a beam bracket 420 and a beam clip 430. As best seen in the aspect depicted in FIGS. 10 and 11, the beam clip 430 is coupled to a post cap 480 and to a first side 411 of the beam 410. The beam bracket 420 is coupled to a second side 412 of the beam 410 and to the post member 450. In the aspect depicted in FIGS. 11 and 12A, the beam bracket 420 is also secured to at least two opposing sides 458 and 460 of the post member 450.

[0042] An example beam bracket 420 is depicted in FIG. 5. In aspects, the beam bracket 420 can include a first portion 421 and a second portion 423 for securing to opposing sides of a post member, e.g., post member 450. In aspects, the beam bracket 420 also includes a third portion 422 for securing to a beam, e.g., the beam 410. In such aspects, this three-sided beam bracket 420 can provide for a secure attachment between a beam and a post assembly.

[0043] An example beam clip 430 is depicted in FIG. 4. In aspects, the beam clip 430 can include a first portion 431 for securing to a post assembly, e.g., the post cap 480 of the post assembly 440. In the same or alternative aspects, the beam clip 430 can include a second portion 433 for securing to a beam, e.g., the beam 410. In certain aspects, the beam clip 430 can include an inverted corner 432 between the first portion 431 and the second portion 433. In aspects, the inverted corner 432 of the beam clip 430 can allow for use of the beam clip to secure a framing member to the beam. [0044] FIG. 12A depicts a post and beam assembly 400 with a framing member 500 coupled to the beam 410. In the aspect depicted in FIG. 12A, the framing member 500 is a perimeter frame member for a decking system, but it should be understood that one or more inner frame members can also or alternatively be coupled to the beam 410 in the manner discussed herein. Further, it should be understood that the framing member 500 depicted in FIG. 12A is just one example of a framing member and that other designs are also contemplated for use in the present system disclosed herein. In the aspect depicted in FIG. 12A, the beam clip 435 is coupled to a top side 413 of the beam 410 and to a portion of the framing member 500.

[0045] FIG. 12B is a close up view of the framing member 500 and the beam 410 from FIG. 12A. As discussed above, the beam clip 435 is coupled to a top side 413 of the beam 410 and to a portion of the framing member 500. As can be seen in FIG. 12B, the framing member 500 includes an engagement member 502, which in this aspect, exhibits a square hook-like shape extending out from the surface 503 of the framing member 500. In various aspects, the inverted comer 436 of the beam clip 435 is shaped and sized to cover the engagement member 502 while the beam clip 435 is coupled to the top end of the beam 413 and to the surface 503 of the framing member 500. In such aspects, the inverted corner 436 of the beam clip 435 can allow for a secure fastening between a beam and a framing member, while accommodating various structural features of the framing member 500, e.g., the engagement member 502.

[0046] In various aspects, other beams can be utilized in the system disclosed herein. For instance, in certain aspects a beam having one or more supports, e.g., in an interior portion, may be utilized to increase the load bearing of the decking system. FIG. 13 depicts one example post and beam assembly that includes a beam 405 having support bolster 407 in an interior portion 406 of the beam 405. In such aspects, the support bolster 407 may extend along the entire length of the beam 405, or extend along a specific portion of the interior portion 406 of the beam 405. FIG. 12B also depicts the position of an optional support bolster in an interior portion of the framing member 500, at the position of the phantom line 505. In various aspects, this optional support bolster may extend along the entire length of the framing member 500, or extend along a specific portion of the interior portion of the framing member 500.

[0047] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. [0048] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

[0049] While specific elements and steps are discussed in connection to one another, it is understood that any element and/or steps provided herein is contemplated as being combinable with any other elements and/or steps regardless of explicit provision of the same while still being within the scope provided herein. Since many possible embodiments may be made of the disclosure without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.

Claims

CLAIMS What is claimed is:

1. A post assembly for a decking system, comprising: a post member, the post member comprising: a first end, a second end opposite the first end, and at least one sidewall; and one or more post caps, wherein each of the one or more post caps comprises a post cover and one or more tabs extending out from the post cover, wherein, when, in an assembled configuration, the one or more tabs of each of the one or more post caps are positioned within one or more slots in an interior portion of the post member.

2. The post assembly of claim 1, wherein the one or more tabs comprise a first tab and a second tab, wherein the first tab and second tab are adjacent to opposing ends of the post cap.

3. The post assembly of claim 2, wherein the at least one sidewall at least partly forms a first side and a second side opposite the first side, a third side and a fourth side opposite the third side, wherein the first side is orthogonal to the third side and the fourth side, and wherein the second side is orthogonal to the third side and the fourth side.

4. The post assembly of any of claims 1-3, wherein each of the one or more slots are formed at least partly by the at least one sidewall and a slot member spaced apart from the at least one sidewall.

5. The post assembly of claim 2 or 4, wherein the first tab is inserted into a first slot and into a second slot of the one or more slots.

6. The post assembly of any of claims 1-5, wherein the one or more slots extend from a position at or adjacent the first end of the post member to a position at or adjacent the second end of the post member.

7. The post assembly of any of claims 1-6, wherein the post member includes one or more fastener-receiving members positioned in the interior portion of the post member.

8. The post assembly of claim 7, wherein the one or more fastenerreceiving members extend from a position at or adjacent the first end of the post member to a position at or adjacent the second end of the post member.

9. The post assembly of claim 4, wherein the post member comprises one or more fastener-receiving members positioned in the interior portion of the post member, and wherein each of the one or more fastener-receiving members comprises two slot members extending out therefrom.

10. The post assembly of any of claims 1-9, wherein each post cap of the one or more post caps comprises one or more through-holes.

11. The post assembly of claim 10, wherein the one or more through-holes comprises a center slot and one or more countersunk holes.

12. The post assembly of claim 11, wherein the post member includes one or more fastener-receiving members positioned in the interior portion of the post member, and wherein, when in an assembled configuration, each of the one or more countersunk holes is aligned with one fastener-receiving member of the one or more fastener-receiving members.

13. The post assembly of any of claims 1-12, wherein the post assembly, when in an assembled configuration, comprises a first post cap of the one or more post caps coupled to the first end of the post, and a second post cap of the one or more post caps coupled to the second end of the post.

14. A post and beam assembly for a decking system, comprising: a post member, the post member comprising: a first end, a second end opposite the first end, and at least one sidewall; and one or more post caps, wherein each of the one or more post caps comprises a post cover and one or more tabs extending out from the post cover, wherein, when in an assembled configuration, the one or more tabs of each of the one or more post caps are positioned within one or more slots in an interior portion of the post member; a beam, the beam comprising first and second opposing sides and opposing top and bottom sides, wherein, when in the assembled configuration, the beam is positioned on top of a first post cap of the one or more post caps; and a first beam clip coupled to a first post cap of the one or more post caps and to the first side of the beam.

15. The post and beam assembly of claim 14, further comprising a beam bracket coupled to the at least one sidewall of the post member and to the second side of the beam.

16. The post and beam assembly of claim 14, wherein the first post cap of the one or more post caps is coupled to the first end of the post member, and wherein a second post cap of the one or more post caps is coupled to the second end of the post member.

17. The post and beam assembly of claim 16, further comprising a framing member coupled to the top side of the beam.

18. The post and beam assembly of claim 17, wherein a second beam clip is coupled to the top side of the beam and a portion of the framing member.

19. The post and beam assembly of claim 17, wherein, when in the assembled configuration, the second beam clip comprises a first portion coupled to the top side of the beam, a second portion coupled to the portion of the framing member, and an inverted corner positioned between the first portion and the second portion, and wherein the inverted corner covers an engagement member of the framing member.

20. The post and beam assembly of claim 16, wherein, when in the assembled configuration, the second post cap is secured to a portion of a support via one or more fasteners extending through a center slot of the second post cap.