OUTDOOR PLATFORM SYSTEM

Description

BACKGROUND

Roofs, pergolas, sheds, canopies, patios, cantilevered umbrellas, and other platformed structures are popular additions to property that offer a variety of enhanced opportunities in leisure and utility. However, installing platformed structures often requires prohibitive time and effort with respect to both anchoring and building a base for the structure.

Consequently, there is a demand for a platform system capable of supporting a variety of structures thereon. Further, there is a demand for such a platform system that may be installed with relative ease from users.

SUMMARY

According to an aspect, a platform system includes a base including a plurality of side beams and at least one deck board. The at least one deck board defines a flooring for the platform system. The platform system also includes at least one corner hub that connects one side beam of the plurality of side beams to another of the side beams of the plurality of side beams. The at least one corner hub cooperates with the plurality of side beams to define a perimeter of the platform system.

The platform system also includes at least one anchor configured to be inserted into ground so as to connect the base to the ground. The at least one anchor includes a distal terminal end configured to be received in the ground and a proximal terminal end disposed at an opposite end thereof. The at least one anchor is disposed so as to be inset from the perimeter.

According to an aspect, a platform system is configured to be disposed above a ground. The platform system includes a deck board including an upper deck surface, and a frame that supports the deck board. The frame includes at least two elongated side beams. Each of the at least two elongated side beams defines a longitudinal axis and includes upper beam surface and two opposing ends. The platform system also includes at least one corner hub being configured to receive and be secured to one of the opposing ends of each of the at least two elongated side beams so that each of the at least two elongated side beams that are secured reside at a first prescribed angle with respect to each other, at least one corner beam attached to each of the two elongated secured side beams and being located a prescribed distance from the at least one corner hub, and at least one anchor contacting the ground. The at least one anchor is located below and directly supporting the at least one corner beam and the at least one corner hub and the two elongated secured side beams above the ground. The upper beam surfaces of the at least two secured side beams support the deck board.

According to an aspect, a corner assembly of a platform system, in which the platform system includes at least one deck board, and at least one horizontal side beam that is disposed above a ground and supported by at least one ground support and defining a centerpoint. The corner assembly includes a corner hub including an upper mounting surface and at least one side mounting surface, the at least one side mounting surface disposed orthogonal to the upper mounting surface; and a corner support bracket extending inwardly towards the centerpoint of the platform system. The upper mounting surface is configured to receive and support an associated vertical column above the at least deck board, the at least one side mounting surface being configured to support the at least one horizontal side beam. Further, the corner support bracket is configured to contact the at least one ground support so that the at least one deck board is supported above the ground in an offset manner through the corner support bracket and the corner hub.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a platform system including a roof;

FIG. 2 is a perspective view of the platform system with the roof and flooring removed;

FIG. 3A is a top plan view of FIG. 2;

FIG. 3B is a bottom plan view of FIG. 2;

FIG. 4 is an elevation view of FIG. 2;

FIG. 5A is a partial perspective detail view of circle F5A of FIG. 2;

FIG. 5B is an exploded view of FIG. 5A;

FIG. 6 is a perspective detail view of circle F6 of FIG. 3B;

FIG. 7 is a partial perspective exploded view of two side beams and a corner hub of the platform system;

FIG. 8 is a top perspective detail view of circle F8 of FIG. 2; and

FIG. 9 is a top perspective view of circle F5A of FIG. 2 with a cap removed.

DETAILED DESCRIPTION

It should, of course, be understood that the description and drawings herein are merely illustrative and that various modifications and changes can be made in the structures disclosed without departing from the present disclosure.

With reference to FIGS. 1-2, a platform system 100 is shown. The platform system 100 can include a base 102, at least one corner hub 104, and at least one anchor 106 for receipt by the ground 108. As will be appreciated, the ground 108 is also known as the surface of the earth, and could be comprised of any number of substances including, for example, but not limited to, soil, clay, dirt, sand, and/or stone.

The platform system 100 can also include at least one corner beam 110, at least one side beam insert 112 (FIG. 7), at least one anchor bracket 114, at least one column 116, a roof 118, a midbeam 120, at least one crossbeam 122, and at least one corner support bracket 124.

The base 102 can include a plurality of side beams 126 and at least one deck board 128. The side beams 126 may be extruded elements and as such, each define a longitudinal void so that additional structures can be attached thereto. For example, the longitudinal void allows for receipt of the least one side beam insert 112, as will be described in more detail hereinafter. The deck board 128 defines a flooring for the platform system 100. As illustrated, there are a plurality of deck boards 128 defining the flooring for the platform system 100. As also illustrated, the deck board 128 are rectangular plank shaped. However, other shapes are possible and contemplated. The deck board 128 could be made from a variety of materials, including metal, natural, or composite materials without departing from the scope of this disclosure.

The base 102 and the roof 118 can each form a rectangular shape in a horizontal direction. However, the base 102 and the roof 118 may additionally or alternatively form a variety of shapes, including elliptical and polygonal shapes without departing from the scope of the present disclosure.

With attention to FIGS. 1-4, the plurality of side beams 126 can include a pair of first side beams 126a, 126a′ that are spaced from and generally parallel to one another and a pair of second side beams 126b, 126b′ that are spaced from and generally parallel to one another. Additionally, as best shown in FIG. 8, the first side beam 126a can include a first side beam flange 130. Further, the first side beam flange 130 can define a flange gap 132a as will be described in more detail hereinafter. Although only one of the beam flanges is shown in detail, it will be appreciated that any of the side beams 126 could include a flange, or a plurality of flanges without departing from the scope of this disclosure. The flange can provide support to the deck board 128, as well as provide an attachment point to the deck board 128, as described in greater detail below.

As illustrated, the plurality of side beams 126 includes four side beams 126a, 126a′, 126b, 126b′. At least one of the plurality of side beams 126 can define an aperture 134 (FIG. 7) as will be discussed in more detail hereinafter. One of the first side beams 126a, 126a′ defines a first axis and one of the second side beams 126b, 126b′ defines a second axis. For example, as shown in FIG. 7, the first side beam 126a defines the first axis and the second side beam 126b defines the second axis. The second axis is generally orthogonal to the first axis.

Accordingly, the two adjacent beams 126a, 126b are connectable orthogonally with respect to each other. Further, the aperture 134 extends primarily in a direction that is parallel to the first axis, which as is shown in FIG. 7, is the first side beams 126a. Additionally, at least one of the side beams 126 defines a bottom channel 126′ (FIG. 6) that faces toward the ground 108. The bottom channel 126′ defines a bottom channel width that is generally orthogonal to a primary direction in which the one side beam 126 extends.

The midbeam 120 can be generally parallel to the side beams 126a, 126a′. Further, the midbeam 120 can be disposed so as to extend between center points of the side beams 126b, 126b′. As illustrated, the midbeam 120 bisects the crossbeam 122 into two portions. However, it will be understood that the crossbeam 122 could be a single element without departing from the scope of this disclosure. Further, although the midbeam 120 is shown as a single element, it is envisioned that the midbeam 120 could be of multiple elements, depending on the structural load requirements of the particular deck use and application. Notably, the crossbeam 122 connects to opposing side beams 126a, 126a′ or 126b, 126b′ at any point there along, depending on the structural load requirements of the final deck. Typically, the crossbeam 122 can be connected to two opposing side beams 126a, 126a′ or 126b, 126b′ at their respective midpoints.

As best shown in FIGS. 2 and 8, the at least one crossbeam 122 can include a crossbeam flange 136 and can be disposed generally parallel to the pair of second side beams 126b, 126b′. The crossbeam flange 136 of the crossbeam 122 can be received or accommodated in the flange gap 132a of the first side beam flange 130. Thus, the first side beam flange 130 and the crossbeam flange 136 can be coplanar to receive or support the at least one deck board 128.

Further, the crossbeam 122 can connect the pair of first side beams 126a, 126a′, through a connection to the midbeam 120, so as to form a pair of rectangles in the plan view (FIGS. 3A-3B). As such, the first side beam flange 130 and the crossbeam flange 136 can cooperate to support the at least one deck board 128. Further, the midbeam 120 can also assist the first side beam flange 130 and the crossbeam flange 136 to support the at least one deck board 128. This layout provides further strength and rigidity to the platform system 100, thereby providing an improved experience for the user. Further, because of the flange gap 132a, the crossbeam flange 136 and the first side beam flange 130 can be coplanar. Therefore, a flat surface is provided for receipt of the deck board 128 and stability is improved.

With reference to FIGS. 1-7, the corner hub 104 can connect one side beam 126a, 126a′, 126b, 126b′ of the plurality of side beams 126 to another of the side beams 126a, 126a′, 126b, 126b′ of the plurality of side beams 126. The corner hubs 104 cooperate with the plurality of side beams 126 to define a perimeter of the platform system 100. As illustrated, the at least one corner hub 104 can include four corner hubs 104′, 104″, 104′″, 104″″. Unless otherwise noted, any discussion related to the corner hub 104 will be understood to be applicable to all of the corner hubs 104′, 104″, 104′″, 104″″.

The four corner hubs 104′, 104″, 104′″, 104″″ can be disposed so as to connect the four side beams 126a, 126a′, 126b, 126b′ in a rectangular shape in plan view (FIGS. 3A-3B). As shown in FIG. 6, the corner hub 104 can include an inner first face 104a and an inner second face 104b that face toward the one side beam 126 of the plurality of side beams 126 and the another of the side beams 126, respectively. The inner first face 104a and the inner second face 104b can also be interchangeably be referred to as side mounting surfaces. The corner hub 104 can also include an outer first face 104c and an outer second face 104d that face in opposite directions as the inner first face 104a and the inner second face 104b, respectively. The corner hub 104 can also include an upper mounting surface 104e that is covered by the cap 156 in FIG. 7. The upper mounting surface 104e is best shown in FIG. 9.

As best shown in FIGS. 6-7, the corner hub 104 can include an inner first face tab 104a′ that extends from the inner first face 104a. With particular attention to FIG. 6, the corner hub 104 can also include an inner second face tab 104b′ that extends from the inner second face 104b. The inner first face tab 104a′ and the inner second face tab 104b′ are configured to vertically support the one side beam 126 of the plurality of side beams 126. This support is valuable not only when the platform system 100 is fully assembled, but also especially valuable during assembly of the platform system 100.

In particular, the inner first face tab 104a′ and the inner second face tab 104b′ provide direct support to the respective beams 126b, 126a during assembly so that fasteners 154 can be easily secured, connecting the beams 126b, 126a to the corner hub 104d. Further, the tabs 104a′, 104b′ can be sized, shaped and positioned to register within the bottom channels 126′ of respective side beams 126. This registration and alignment between the tabs and the respective bottom channels ensures proper horizontal and vertical alignment between the beam 126 and the connecting corner hub 104.

The inner first face 104a defines an inner face length, an inner face width, and an inner face height, and the inner face tab defines an inner face tab length, an inner face width, and an inner face height. The inner face length, the inner face width, and the inner face height are individually greater than any of the inner face tab length, the inner face width, or the inner face height so that the inner face tab can be received in the bottom channel 126′ of the one side beam 126.

Because of the size of the inner first face tab 104a′ and the inner second face tab 104b′, the inner first face tab 104a′ and the inner second face tab 104b′ can be received by bottom channel 126′ of the corresponding side beam 126. Thus, the user may reliably position and support the side beams 126 on the corner hub 104 when assembling the base 102 with ease. Further, the inner first face tab 104a′ and the inner second face tab 104b′ can support the side beams 126 on the corner hub 104 during use of the platform system 100 to provide additional rigidity to the assembly.

With reference to FIGS. 1-4, and particular attention to FIG. 1, the anchor 106 is configured to be inserted into the ground 108 so as to connect the base 102 to the ground 108. The anchor can also support the weight of the assembly. The anchor 106 can interchangeably also be referred to as a ground support without departing the from the scope of this disclosure. As shown in FIG. 4, the anchor 106 includes a distal terminal end 106′ that is configured to be received in the ground 108 and a proximal terminal end 106″ that is disposed at an opposite end and is configured to reside above the ground 108. The at least one anchor 106 can include at least four anchors 106. As will be appreciated, the greater the expected load of the deck assembly, the more anchors 106 can be utilized.

As shown in FIGS. 3A-3B, the anchor 106 can include anchors 106a, 106b, 106c, 106d and a center anchor 106e, with the anchors 106a, 106b, 106c, 106d being disposed near corners of the base 102, with the center anchor 106e being disposed near a lateral and longitudinal center of the base 102. While the construction of the anchors 106a, 106b, 106c, 106d is the same as the center anchor 106e, the layout of the anchors 106a, 106b, 106c, 106d is different than the center anchor 106e.

Accordingly, unless otherwise noted, any description related to the construction of the anchor(s) will be understood to be applicable to the anchors 106a, 106b, 106c, 106d and the center anchor 106e, but any reference to the layout of the anchor(s) will be limited to the anchors 106a, 106b, 106c, 106d and not the center anchor 106e. It is noted that the center anchor 106e is not required. Alternatively, the center anchor 106e could be replaced by a variety of elements without departing from the scope of this disclosure. For example, concrete footings or supportive feet could be utilized.

As shown in FIG. 3A, the four anchors 106a, 106b, 106c, 106d can be disposed such that a first imaginary line F that connects two 104′, 104′″ or 104″, 104″″ of the four corner hubs 104 that are diagonally disposed across from one another passes through two 106a, 106c or 106b, 106d of the four anchors 106 in a plan view so as to define a first line length. As shown in FIG. 3B, a second imaginary line S connects the two 106a, 106c or 106b, 106d of the four anchors 106 in the plan view so as to define a second line length. Then, the second line length would be less than the first line length.

With continued attention to FIGS. 3A-3B, stated another way, the anchor 106 is disposed so as to be inset from the perimeter. Further, the anchor 106 is disposed so as to be between the pair of first side beams 126a, 126a′ and between the pair of second side beams 126b, 126b′ in a plan view. The at least one anchor 106 is laterally and longitudinally inset from the at least one corner hub 104.

With the anchor 106 being inset, numerous advantages are provided. For example, a better aesthetic appeal is provided, as the clean lines of the beams are not broken when viewed by a user. It allows the deck to appear floating above the ground, a desired aesthetic. Further, tripping hazards are reduced with the anchor 106 being located inset.

As best illustrated in FIGS. 5A-5B, the anchor 106 includes a mounting portion 138 at the proximal terminal end 106″ that defines at least one arcuate slot 142 for engagement with the anchor bracket 114 as will be described in more detail hereinafter. Additionally, the corner beam 110 can extend between and connect one of the first side beams 126a, 126a′ and one of the second side beams 126b, 126b′ together so as to be inset from the perimeter. The corner beam 110 can be positioned any distance from the corner hub 104, depending on the structural, materials, and expected load details, and can also be oriented along any angle with respect to either connected side beam. However, a typical angle can be 45 degrees, as shown in FIG. 5A.

As shown in FIG. 3A, the corner beam 110 can cooperate with the connected first side beam 126 and the connected second side beam 126 so as to define a triangle shape in a plan view. The corner beam 110 defines at least one corner beam channel 110′ (FIG. 5A-5B). This triangular shape provides increased strength to the platform system 100. Thus, users of the platform system 100 are provided a sturdy surface upon which to relax.

With continued attention to FIGS. 5A-5B, the anchor bracket 114 connects the anchor 106 to the corner beam 110. Further, the anchor bracket 114 includes a lower portion 144 that defines a plurality of lower portion slits 146 for attachment to the at least one anchor 106 and an upper portion 148 that is slidably received by the at least one corner beam channel 110′ of the at least one corner beam 110. The arcuate slot 142 of the anchor 106 is configured for receipt of a fastener that extends from the plurality of lower portion slits 146 of the at least one corner beam 110 so as to slidable connect the at least one anchor 106 with the at least one corner beam 110.

Because of slidable arrangement provided by the corner beam 110 channel and also the arcuate slot 142 of the anchor 106, the anchor 106 can be diagonally moved with respect to the side beams 126 and also rotated with respect to the anchor bracket 114, thus allowing a position of the anchor 106 with respect to the ground 108 to be modified. Accordingly, if obstructions in the ground 108 were identified during installation of the platform system 100, the anchor 106 could be moved to avoid these obstructions, while still allowing the platform system 100 to be installed in the desired location.

As best shown in FIGS. 5A-5B, the corner support bracket 124 can extend from the at least one corner hub 104 to the at least one corner beam 110 that connects the connected first side beam 126 and the connected second side beam 126 together. Thus, the corner support bracket 124 bisects the triangle shape into two further triangle shapes in the plan view (FIG. 3A). By creating these triangle shapes, the connection strength between the corner beam 110 and the side beams 126 greatly improved, thereby resulting in a platform system 100 that is steady even in less than ideal mounting locations.

With reference to FIG. 7, the side beam insert 112 is selectively separable from the side beam 126b and defines at least one threaded hole 152. The aperture 134 of the side beam 126b is configured for slidingly receiving the side beam insert 112. Further, the side beam insert threaded hole 152 is configured for receiving a side beam fastener 154 that extends from the at least one corner hub 104. The side beam insert 112 could include one or a plurality of holes for receiving a fastener.

Because of the side beam insert 112 and aperture 134, a more aesthetically pleasing assembly is provided to the user. This aesthetically pleasing assembly is further enhanced with the fasteners used to secure the side beams 126 to respective corner hubs 104 are hidden from outside view. Additionally, assembly of the platform system 100 is simplified, as the aperture 134 is sized and shaped to prevent rotation of the side beam insert 112, unlike if a nut and bolt arrangement was utilized. As such, the assembler of the platform system 100 does not need to prevent rotation of the side beam insert 112 while the side beam fastener 154 is being rotated.

As the corner hub 104 can be hollow, the side beam fasteners 154 can be tightened by rotating heads of the fasteners 154 from within the corner hub 104. Access to the fasteners 154 is provided when a cap 156 (FIG. 5A) is removed, as shown in FIG. 9. As the bolts 154 are tightened, they pull the insert 112, and therefore also the side beam 126b into tight surface engagement with the inner first face 104a, thereby effectively mechanically affixing side beam 126b with the corner hub 104. The beam is further supported by the tab 104a′.

With reference back to FIG. 1, the columns 116 are configured to support the roof 118 above the base 102 and extend perpendicularly above corner hubs 104. Further, this extension of the columns 116 from the corner hubs 104 is in a direction that is opposite to a direction that the anchor 106 extends when extending from the proximal distal end to the distal terminal end 106′. Thus, the column 116 extends upwardly and away from the ground 108 from the at least one corner hub 104 so as to form an orthogonal connection in an elevation view of the platform system 100.

Further, the one side beam 126 of the plurality of side beams 126 is connected to the another of the side beams 126 of the plurality of side beams 126 with the at least one corner hub 104 to form an alternative orthogonal connection in the elevation view and the at least one column 116 extends from the corner hub 104 so as to define a third axis. This orthogonal connection between the components provides increased strength to the platform system 100. In particular, the orthogonal connection results in the entire platform system 100 being considered a single component for rigidity purposes. By allowing the columns 116 to be connected directly to the corner hubs 104, not only is a strong connection made, but the fasteners can be hidden from view.

The roof 118 can be fixed with the columns 116. With this construction, the roof 118 can extend over and across the entire base 102 from the corner hubs, as supported by the columns 116, or a portion thereof. The roof 118 can include main beams that are directly connected to, and extend between the columns 116 along the perimeter of the base 102. The roof 118 can also include slats fixed between the main beams. The slats may be arranged to form a lattice that extends over and across the base 102 with the main beams, or a portion thereof.

Attention is now directed to FIG. 9, which is a top perspective view of circle F5A of FIG. 2 with the cap 156 removed. With the cap 156 removed, easy access to the upper mounting surface 104e of the corner hub 104 is provided. Because of the cap 156, the platform mounting system 100 can be utilized in a variety of manners. For example, the platform system 100 can be offered without a roof 118. When the roof 118 is not provided with the platform system 100, the cap 156 can be placed on the upper mounting surface 104e so as to provide a clean and clear design surface.

Alternatively, the platform system 100 can include the roof 118 as previously described. Notably, when the roof 118 is desired, the cap 156 is removed from the upper mounting surface 104e of the corner hub 104 and a column bracket 158 is provided. In particular, the column bracket 158 can be attached to the upper mounting surface 104e of the corner hub 104 by a variety of techniques that are known. These techniques could include, for example, bolts/nuts, screws, rivets, adhesive, and other types of press fitting and joining techniques. Once the column bracket 158 is attached to the upper mounting surface 104e of the corner hub 104, the column 116 can be connected to the column bracket 158.

As illustrated, the column bracket 158 can be slidably received by the column 116. This slidable arrangement provides a sleek appearance for the platform system 100 and can be desirable for users. As will be appreciated, a number of ways can be used to secure the column 116 and the column bracket 158 together. For example, fasteners or keys could be inserted through the holes in the column 116 to engage the column bracket 158. However, other ways are possible and contemplated.

Unless otherwise noted, the components of the platform assembly 100 can be made from a variety of materials that provide sufficient rigidity to allow users to relax on the platform system 100 and be resistant to damage from the outdoor elements. The materials could include a strong lightweight material such as aluminum, with the corner hubs 104 being either cast aluminum or fabricated from sheet metal, cut, bent, formed and welded together as understood by those of ordinary skill in the art. Elongated components may be made from extruded aluminum. In an embodiment, an aluminum alloy forming all the aluminum components described in this application is alloy 6063T6.

Each of the columns 116, the corner hubs 104 and the side beams 126 can include exterior fascia that faces outward from the perimeter of the base 102. The exterior fascia can be flush across adjacent portions of the corner hubs 104, the columns 116, and the side beams 126. With this construction, each of the corner hubs 104, the columns 116, and the side beams 126 are flush with adjacent portions of each other along an exterior of the platform system 100.

The fascia can be decorative and be made from a variety of materials including wood, plastic, composite materials, metal, ceramic, glass, and any combination thereof. The fascia can further be used to cover electrical wires or plumbing, mechanical connections and fasteners, and support various accessories, such as window and sliding door tracks and tracks for screens and wind-break panels. The main purpose of the fascia boards is to hide the otherwise exposed side beams with a designed surface treatment that works aesthetically well with the decking.

It will be appreciated that various of the above-disclosed embodiments and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.