Joist Assemblies and Assembly Kits
A joist assembly kit according to various embodiments comprises: (A) a first joist comprising: (1) a first casing; (2) a tenon that is disposed adjacent an end portion of the first casing; and (3) a first reinforcing member that extends: (a) longitudinally within the interior of both the casing and the tenon, (b) out of the tenon's interior, and (c) adjacent an end surface of the tenon; and (B) a second joist that comprises: (1) a second casing; and (2) a second reinforcing member that extends longitudinally within an the second casing's interior. In particular embodiments: (1) the second casing defines a mortise; (2) the tenon is adapted so that when the tenon is inserted into the second joist's mortise, the tenon matingly engages the second joist about a perimeter of the mortise. The joists may be attached together by fastening their respective reinforcing members together with a suitable fastener.
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This application is a continuation-in-part of U.S. patent application Ser. No. 12/725,618, which was filed on Mar. 17, 2010, and which is hereby incorporated by reference in its entirety.
BACKGROUNDCurrently, most decks are made of wood. However, there are several disadvantages associated with using wood to build decks and other structures. For example, although wood has proven to be a suitable, relatively inexpensive decking material, wooden decks tend to fade and splinter over time. Also, out of concern for a decreasing supply of natural resources, many consumers prefer to avoid using wood as a building material. Wood boards can also be relatively heavy and expensive.
Although alternative decking products are currently used, in some cases, for the surfaces of decks, the structural portions of such decks (e.g., the decks' posts, beams, and joists) are still typically made of wood. This is due to challenges in producing a low maintenance product that has the structural integrity to support the alternative deck surfacing products that are available on the market today.
Accordingly, there is a need for new building materials, such as decking materials (e.g., floor, ceiling, and band joists), that are durable, lightweight, inexpensive, and environmentally friendly.
SUMMARYA joist assembly kit according to particular embodiments comprises a first joist that includes (1) a first elongated casing that is substantially in the form of a rectangular prism (or other suitable shape); (2) a tenon that is disposed adjacent an end portion of the first elongated casing; and (3) a first reinforcing member that: (A) extends longitudinally within an interior of the first elongated casing; and (B) extends longitudinally within an interior of the tenon. A particular portion of the first reinforcing member extends out of the interior of the tenon and is disposed adjacent (e.g., folds over) a particular end surface of the tenon.
The joist assembly kit further includes a second joist that comprises a second elongated casing that is substantially in the form of a rectangular prism (or other suitable shape); and a second reinforcing member that extends longitudinally within an interior of the second elongated casing. In particular embodiments: (1) the second elongated casing defines at least one mortise; (2) the second reinforcing member defines a particular exterior surface of the second joist immediately adjacent the mortise; (3) the particular surface of the second joist at least partially defines the mortise; and (4) the tenon of the first joist is adapted and dimensioned so that when the tenon is inserted into the second joist's mortise, the first joist's tenon matingly engages the second joist about a perimeter of the mortise.
When particular embodiments of the joist assembly kit are assembled, they form a joist assembly in which the first joist's tenon matingly engages the second joist about a perimeter of the mortise, and the particular portion of the first metal reinforcing member engages the particular portion of the second metal reinforcing member. The first and second joists may be attached together by fastening their respective reinforcing members together with a suitable fastener.
Having thus described various embodiments of the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
Various embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which various embodiments of the invention are shown. The inventions may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
First Exemplary Reinforced BoardA reinforced board (e.g., a reinforced joist 10, such as a floor joist) according to a particular embodiment is shown in
As may be understood from
In the embodiment shown in
The reinforcing member 100 further includes a first extension portion 102 that, in various embodiments, is substantially planar (e.g., planar). In particular embodiments, such as the embodiment shown in
As may be understood from
In the embodiment shown in
As may be understood from
In the embodiment shown in
As may be understood from
Turning further to
This third length of material 130 is mounted below: (1) the first and second lengths of material 110, 120; and (2) the second extension portion 103 of the reinforcing member 100. In particular embodiments, such as the embodiment shown in
Turning again to
This fourth length of material 140 is mounted above: (1) the first and second lengths of material 110, 120; and (2) the first extension portion 102 of the reinforcing member 100. In particular embodiments, such as the embodiment shown in
In various embodiments, the first, second, third and fourth lengths of material 110, 120, 130, 140, and the reinforcing member 100 are attached together in the arrangement shown in
As noted above, and as shown in
As shown in
A second exemplary reinforced board (e.g., a reinforced joist, such as a band joist 15, 151) according to a particular embodiment is shown in
In other embodiments, such as when the band joist is used as an end band joist 151, the end band joist 151 includes no mortises 40.
In particular embodiments, the band joist's body portion 211 has a substantially uniform cross section along the length of the body portion 211, except where a portion of the cross section (e.g., the second length of material 220 referenced below) has been removed to create a recess (e.g., a mortise 40) in the band joist 15 (See
As may be understood from
In the embodiment shown in
As may be understood from
In the embodiment shown in
As may be understood from
In the embodiment shown in
Turning further to
This third length of material 230 is mounted below: (1) the first and second lengths of material 210; and (2) the second extension portion 203 of the reinforcing member 200. In particular embodiments, such as the embodiment shown in
Turning again to
This fourth length of material 240 is mounted above: (1) the first and second lengths of material 210, 220; and (2) the first extension portion 202 of the reinforcing member 200. In particular embodiments, such as the embodiment shown in
In various embodiments, the first, second, third and fourth lengths of material 210, 220, 230, 240, and the reinforcing member 200 are attached together in the arrangement shown in
As noted above, each floor joist 10 comprises two tenons 125, each of which extends from a respective end of the joist 10. These tenons 125 are substantially in the form of a rectangular prism, and the body portion 101 of the joist's reinforcing member 100 (which, in various embodiments, is made of steel) folds over (or otherwise extends adjacent) and is attached to the end of the tenons 125.
To assemble the deck frame, an individual first attaches a first side of each of: (1) the deck frame's floor joists 10; and (2) the deck frame's end band joists 151 to one of the deck frame's side band joists 15 (or to one co-linear set of side band joists 15 if multiple side band joists are used to define one side of the deck band). As noted above, in the embodiment shown in
To attach one of the deck frame's floor joists 10 to one of the deck frame's side band joists 15, the user inserts the floor band joist's tenon 125 into a respective mortise 40 within the side band joist 15, and affixes the tenon 125 in place within the mortise 40 (e.g., by using suitable hardware and/or adhesives).
For example, to attach a first side of one of the deck frame's floor joists 10 to one of the deck frame's side band joists 15, the user first coats the floor joist's tenon 125 with PVC glue and inserts the tenon 125 into a mortise 40 defined by the first side band joist 15 as shown in
After the individual attaches a first side of each of: (1) the deck frame's floor joists 10; and (2) the deck frame's end band joists 151 to one or more of the deck frame's side band joists 15 as described above, the individual attaches, in the manner described above, a second side of each of: (1) the deck frame's floor joists 10; and (2) the deck frame's end band joists 151 to another one of the deck frame's side band joists 15 (or to one co-linear set of side band joists 15 if multiple side band joists are used to define one side of the deck band). This step typically completes the deck frame assembly process.
In light of the discussion above, it should be understood that, in various embodiments, when the deck frame 7 is entirely assembled, the reinforcing members 100, 200 of the various joists 10, 15, 151 are at least substantially encased (e.g., entirely encased) in other components of the joists 10, 15, 151 (e.g., in the joists' respective first, second, third, and fourth lengths of material which may, for example, be polystyrene). This may, in particular embodiments, serve to at least substantially insulate the reinforcing members 100, 200 from the atmosphere. This may reduce the possibility that the reinforcing members 100, 200 will rust or otherwise degrade over time.
Alternative Board StructuresIt should be understood that the structure of the various reinforced board structures described above may vary in other embodiments of the invention. For example, the relative sizes of the various components of the board may be different than those described above. For example, the joist 35 of
It should also be understood that the shape, position, and relative size of the reinforcing member may vary among different embodiments of the invention. For example, the reinforcing member may be substantially in the form of an I, an L, or an O.
Similarly, although various embodiments of the reinforced boards are described above as having plastic first, second, third, and fourth lengths of material, it should be understood that, in other embodiments, these components may be made of any other suitable material, such as wood or fiberglass. Also, although the first, second, third, and fourth lengths of material are described above as being in the form of at least substantially rectangular prisms, these components can be of any other suitable shape.
In addition, it should be understood, in light of this disclosure, that the board structures described herein may be used in the context of a variety of different building materials, such as posts, beams, and other types of joists.
CONCLUSIONMany modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, as will be understood by one skilled in the relevant field in light of this disclosure, the invention may take form in a variety of different mechanical and operational configurations. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for the purposes of limitation.
Claims
1. A joist assembly kit comprising:
- a) a first joist comprising: a first elongated casing that is substantially in the form of a rectangular prism; a tenon that is disposed adjacent an end portion of said first elongated casing; and a first reinforcing member that: (1) extends longitudinally within an interior of said first elongated casing; and (2) extends longitudinally within an interior of said tenon, wherein: a particular portion of said first reinforcing member extends out of said interior of said tenon and folds over a particular end surface of said tenon; and
- b) a second joist comprising: a second elongated casing that is substantially in the form of a rectangular prism; and a second reinforcing member that extends longitudinally within an interior of said second elongated casing, wherein: said second elongated casing defines at least one mortise; said second reinforcing member defines a particular exterior surface of said second joist immediately adjacent said mortise; said particular surface of said second joist at least partially defines said mortise; and said tenon of said first joist is adapted and dimensioned so that when said tenon is inserted into said second joist's mortise, said first joist's tenon matingly engages said second joist about a perimeter of said mortise.
2. The joist assembly kit of claim 1, wherein said first and second elongated casings are plastic casings.
3. The joist assembly kit of claim 1, wherein said first reinforcing member is a metal reinforcing member.
4. The joist assembly kit of claim 2, wherein:
- said second reinforcing member is a metal reinforcing member; and
- said particular surface of said second joist is a particular metal surface.
5. The joist assembly kit of claim 4, wherein:
- said first and second elongated casings are plastic casings.
6. The joist assembly kit of claim 5, wherein:
- said first and second joists are adapted and dimensioned so that, when said first joist's tenon is inserted into said second joist's mortise and said tenon matingly engages said second joist about a perimeter of said mortise, said particular metal surface of said second joist engages said particular portion of said first metal reinforcing member.
7. The joist assembly kit of claim 6, wherein:
- said particular metal surface is substantially planar;
- said particular portion of said first metal reinforcing member is substantially planar; and
- when said particular metal surface of said second joist engages said particular portion of said first metal reinforcing member, said particular metal surface and said first metal reinforcing member are substantially parallel to each other.
8. The joist assembly kit of claim 7, wherein:
- said particular metal surface and said particular portion of said first metal reinforcing member are adapted so that, when said particular metal surface of said second joist engages said particular portion of said first metal reinforcing member, a user may drive a fastener through said particular metal surface of said second joist and said particular portion of said first metal reinforcing member to facilitate attachment of said first joist to said second joist.
9. The joist assembly kit of claim 5, wherein said first metal reinforcing member has a substantially Z-shaped cross-section.
10. The joist assembly kit of claim 5, wherein said second metal reinforcing member has a substantially U-shaped cross-section.
11. The joist assembly kit of claim 5, wherein said first elongated plastic casing comprises a plurality of elongated plastic structures that are disposed circumferentially about said first metal reinforcing member.
12. The joist assembly kit of claim 11, wherein said second elongated plastic casing comprises a plurality of elongated plastic structures that are disposed circumferentially about said second metal reinforcing member.
13. The joist assembly kit of claim 5, wherein:
- said first and second joists are configured so that when said tenon is inserted into said second joist's mortise, said first and second plastic casings at least substantially insulate both said particular metal surface of said second joist and said particular portion of said first metal reinforcing member from the atmosphere adjacent the exterior of said first and second joists.
14. The joist assembly kit of claim 1, wherein a particular length of plastic material defines at least a portion of both said first elongated plastic casing and said tenon.
15. The joist assembly kit of claim 14, wherein:
- said particular length of plastic material is a first particular length of material; and
- said first joist comprises a second particular length of material that defines at least a portion of both said first elongated plastic casing and said tenon.
16. The joist assembly kit of claim 15, wherein said first and second particular lengths of material are disposed on opposite sides of said first metal reinforcing member.
17. A joist assembly kit comprising:
- a) a first joist comprising: a first elongated plastic casing that is substantially in the form of a rectangular prism; a tenon that is disposed adjacent an end portion of said first elongated plastic casing; and a first metal reinforcing member that: (1) extends longitudinally within an interior of said first elongated plastic casing; and (2) extends longitudinally within an interior of said tenon, wherein: a particular portion of said first metal reinforcing member extends out of said interior of said tenon adjacent a particular end surface of said tenon; and
- b) a second joist comprising: a second elongated plastic casing that is substantially in the form of a rectangular prism; and a second metal reinforcing member that extends longitudinally within an interior of said second elongated plastic casing, wherein: said second elongated plastic casing defines at least one mortise; said tenon of said first joist is adapted and dimensioned so that when said tenon is inserted into said second joist's mortise, said first joist's tenon matingly engages said second joist about a perimeter of said mortise; and said first and second joists are adapted and dimensioned so that a particular portion of said first metal reinforcing member engages a particular portion of said second metal reinforcing member when said tenon is inserted into said second joist's mortise.
18. The joist assembly kit of claim 17, wherein said joist assembly kit further comprises at least one fastener that is adapted to fasten said first and second joists together by extending through both:
- a) said particular portion of said first metal reinforcing member; and
- b) said particular portion of said second metal reinforcing member.
19. The joist assembly kit of claim 18, wherein said first metal reinforcing member has a substantially Z-shaped cross-section.
20. The joist assembly kit of claim 18, wherein said second metal reinforcing member has a substantially U-shaped cross-section.
21. The joist assembly kit of claim 20, wherein:
- said first elongated plastic casing comprises a plurality of elongated plastic structures that are disposed circumferentially about said first metal reinforcing member; and
- said second elongated plastic casing comprises a plurality of elongated plastic structures that are disposed circumferentially about said second metal reinforcing member.
22. The joist assembly kit of claim 17, wherein:
- said first and second joists are configured so that, when said tenon is inserted into said second joist's mortise said first and second plastic casings at least substantially insulate both said particular metal surface of said second joist and said particular portion of said first metal reinforcing member from the atmosphere.
23. A joist assembly comprising:
- a) a first joist comprising: a first elongated casing that is substantially in the form of a rectangular prism; a tenon that is disposed adjacent an end portion of said first elongated casing; and a first reinforcing member that: (1) extends longitudinally within an interior of said first elongated casing; and (2) extends longitudinally within an interior of said tenon, wherein: a particular portion of said first reinforcing member extends out of said interior of said tenon and folds over a particular end surface of said tenon; and
- c) a second joist comprising: a second elongated casing that is substantially in the form of a rectangular prism; and a second reinforcing member that extends longitudinally within an interior of said second elongated casing, wherein: said second elongated casing defines at least one mortise; said second reinforcing member defines a particular exterior, surface of said second joist immediately adjacent said mortise; said particular surface of said second joist at least partially defines said mortise; and said tenon of said first joist is disposed within said second joist's mortise, and said first joist's tenon matingly engages said second joist about a perimeter of said mortise.
24. The joist assembly of claim 23, wherein:
- said first and second elongated casings are plastic casings;
- said first reinforcing member is a metal reinforcing member;
- said second reinforcing member is a metal reinforcing member; and
- said particular surface of said second joist is particular metal surface.
25. The joist assembly of claim 24, wherein:
- said first and second joists are adapted and dimensioned so that, when said first joist's tenon is inserted into said second joist's mortise and said tenon matingly engages said second joist about a perimeter of said mortise, said particular metal surface of said second joist engages said particular portion of said first metal reinforcing member.
26. The joist assembly of claim 25, wherein:
- said particular metal surface is substantially planar;
- said particular portion of said first metal reinforcing member is substantially planar, and
- when said particular metal surface of said second joist engages said particular portion of said first metal reinforcing member, said particular metal surface and said first metal reinforcing member are substantially parallel to each other.
27. The joist assembly of claim 26, wherein:
- said particular metal surface and said particular portion of said first metal reinforcing member are adapted so that, when said particular metal surface of said second joist engages said particular portion of said first metal reinforcing member, a user may drive a fastener through said particular metal surface of said second joist and said particular portion of said first metal reinforcing member to facilitate attachment of said first joist to said second joist.
28. The joist assembly kit of claim 27, wherein:
- said first metal reinforcing member has a substantially Z-shaped cross-section;
- said second metal reinforcing member has a substantially U-shaped cross-section.
Type: Application
Filed: Mar 18, 2010
Publication Date: Sep 22, 2011
Applicant:
Inventor: Douglas K. Dueker (Jasper, GA)
Application Number: 12/727,140
International Classification: E04B 1/21 (20060101); E04B 1/24 (20060101); E04H 12/08 (20060101);