Abstract:
In an exemplary embodiment, a modular deck tile is designed to allow for the easy installation of roof top or balcony decks over existing surfaces, such as rolled roofing, waterproof or impermeable membranes. Advantages include the ability to be installed on a roof top surface without penetrating any waterproof membrane layers and cause leaking. The deck tiles may be made with recycled fiber composite decking or high density foam modular tiles. In another exemplary embodiment, the deck tile comprises an interlocking polyethylene base configured for the attachment of composite products or high density foam to be attached either in variety of shape configurations and in a variety of colors.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a non-provisional of U.S. Provisional Application No. 61/222,369, entitled “MODULAR DECK TILE,” which was filed on Jul. 1, 2009, which is hereby incorporated by reference for any purpose in its entirety. 
     
    
     SUMMARY 
       [0002]    In an exemplary embodiment, a modular deck tile is designed to allow for the easy installation of roof top or balcony decks over existing surfaces, such as rolled roofing, waterproof or impermeable membranes. Advantages include the ability to be installed on a roof top surface without penetrating any waterproof membrane layers and cause leaking. The deck tiles may be made with recycled fiber composite decking or high density foam modular tiles. In another exemplary embodiment, the deck tile comprises an interlocking polyethylene base configured for the attachment of composite products or high density foam to be attached either in a variety of shape configurations and in a variety of colors. 
         [0003]    Furthermore, LED lighting may be added to the decking material and used to create various lighting designs. In an exemplary embodiment, the deck tiles comprise power connections configured to provide power to the decking tiles via a grid system that does not require wiring between the individual deck tiles. This grid system of providing power is beneficial in terms of assembly simplicity and time needed to create the lighted deck system. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         [0004]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like reference numbers refer to similar elements throughout the drawing figures, and: 
           [0005]      FIGS. 1   a  and  1   b  illustrate a top view and a side view of an exemplary embodiment of a grid base of a deck tile; 
           [0006]      FIG. 2  illustrates a bottom view of an exemplary embodiment of a grid base of a deck tile; 
           [0007]      FIG. 3  illustrates a perspective view of the top of an exemplary embodiment of a grid base; 
           [0008]      FIG. 4  illustrates a perspective view of the bottom of an exemplary embodiment of a grid base; 
           [0009]      FIG. 5  illustrates a sectional view of an exemplary dual beveled fastener point of a grid base; 
           [0010]      FIG. 6  illustrates a sectional view of an exemplary alignment tab and a grid base; 
           [0011]      FIG. 7   a  illustrates a perspective view of the top of an exemplary embodiment of a grid base; 
           [0012]      FIG. 7   b  illustrates a close-up perspective view of the top of an exemplary embodiment of a grid base; 
           [0013]      FIG. 8   a  illustrates a perspective view of the bottom of an exemplary embodiment of a grid base; 
           [0014]      FIG. 8   b  illustrates a close-up perspective view of the bottom of an exemplary embodiment of a grid base; 
           [0015]      FIG. 9  illustrates an exemplary embodiment of a reducer piece; 
           [0016]      FIG. 10  illustrates an exemplary embodiment of four deck tiles; 
           [0017]      FIG. 11  illustrates a close-up view of a grid base with an alignment tab in an exemplary embodiment; 
           [0018]      FIGS. 12   a  and  12   b  illustrate an exemplary power grid system contained in a deck tile; and 
           [0019]      FIG. 13  illustrates an exemplary embodiment of a light harness connected to a power source and connected to decking material. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    While exemplary embodiments are described herein in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be realized and that logical material, electrical, and mechanical changes may be made without departing from the spirit and scope of the invention. Thus, the following detailed description is presented for purposes of illustration only. 
         [0021]    In accordance with an exemplary embodiment, modular deck tiles are used to form a new decking surface on top of existing surfaces. The existing surfaces may include a concrete surface, a roof top surface, surfaces with waterproof membranes, brick surfaces, compacted earth, a wood framework, or any suitable level surface. In an exemplary embodiment, the deck tiles are free-floating on the underneath surface. In other words, the deck tiles are not screwed, nailed, or bonded to the underneath surface. An advantage of a free-floating deck system is that the deck system prevents the propagation of cracks or other settling issues in the existing surfaces. In other words, cracks appearing in the existing surface will not cause a free-floating surface deck system to similarly crack. A modular deck tile system is used to easily cover an existing surface with minimal structural changes or costly installation. 
         [0022]    In accordance with an exemplary embodiment and with reference to  FIG. 1 , a deck tile  100  comprises a grid base  101 , a plurality of feet  110  connected to grid base  101 , and a plurality of fastener points  120  also connected to grid base  101 . In an exemplary embodiment, deck tile  100  further comprises a shaped outer edge  130  configured to attach to another deck tile. For example, the edge of deck tile  100  may be shaped for a dovetail connection with another deck tile. In an exemplary embodiment, shaped outer edge  130  facilitates the connection of two deck tiles  100  such that a gap of less than ¼ inch results. In one embodiment, two deck tiles are connected with a gap of 3/16 inch between them. In general, a smaller gap space is more aesthetically pleasing to consumers than a larger gap. In an exemplary embodiment, deck tile  100  is 12″ square by ½″ thick, though other suitable dimensions are considered. 
         [0023]    In an exemplary embodiment, deck tile  100  is made of many different combinations of plastic including polypropylene, polyethylene, ethylene vinyl acetate (EVA), or the like. Furthermore, in an exemplary embodiment, grid base  101  is configured to allow water to drain freely under the deck tiles by allowing space between deck tile  100  and the underneath surface. Furthermore, the open structure of grid base  101  prevents mold growth by facilitating air circulation around the tiles. 
         [0024]    In addition to shaped outer edge  130 , in an exemplary embodiment and with reference to  FIG. 2 , deck tile  100  further comprises alignment tabs  140 . In an exemplary embodiment, and with reference to  FIGS. 2 ,  4 ,  6 ,  7   a ,  7   b ,  8   a ,  8   b  and  11 , alignment tabs  140  are built into the sides of grid base  101  and enable the tiles to be quickly, easily and accurately installed. They also provide a strong and secure means of locking each tile to the adjacent tiles. Alignment tabs  140  also facilitate lining up deck tiles  100  for installation. For example, alignment tabs  140  help to align the top surface of a first deck tile flush with the top surface of a second deck tile. In an exemplary embodiment, there is some space between the joints to allow for alignment tab  140  to slide down the face of the dovetail, and then alignment tab  140  helps lock the first and second deck tiles into position once the two top planes are aligned. In accordance with an exemplary embodiment and with momentary reference to  FIG. 6 , alignment tab  140  has a tapered shape to facilitate assembly. In other embodiments, alignment tab  140  has a rounded or square shape to facilitate assembly. In a first embodiment, alignment tab  140  is on the bottom surface of deck tile  100 , along with the plurality of feet  110 . In another embodiment, alignment tab  140  is on the top surface of deck tile  100  where decking material is attached, opposite the plurality of feet  110 . 
         [0025]    An advantage of the module deck tile system is that deck tile  100  can be removed from a deck tile system without requiring additional deck tiles to be removed. In an exemplary embodiment, deck tile  100  is made of flexible material, which facilitates the connection and disconnection of the tiles. Specifically, alignment tab  140  is able to slide down the face of shaped outer edge  130  because the edge of deck tile  100  is flexible enough to accommodate the displacement caused by alignment tab  140 . Furthermore, the various alignment tabs  140  are offset from each other when connecting two deck tiles  140  together. Moreover, in an exemplary embodiment, in order to disconnect a deck tile from the deck tile system without removing additional tiles, a user pries the edge of deck tile  100  away from the adjacent tile until there is sufficient space to allow alignment tab  140  to release. 
         [0026]    In an exemplary embodiment, each of the plurality of feet  110  is round shaped and/or not-pointed. The plurality of feet  110  are configured to distribute the weight of the decking tile and objects on the deck. In an exemplary embodiment, a deck tile comprises 4-16 feet per tile. In one embodiment, there are eight feet in a deck tile as shown in  FIG. 1 . However, any suitable number of feet may be used per deck tile. The shape of the plurality of feet  110  is designed to not penetrate waterproof membranes, which would negatively result in leaks. Thus, in an exemplary embodiment, a modular deck tile provides a modular, surface installed deck tile that spreads point loads to protect waterproof coatings or membranes utilizing fiber composite decking or high density foam. In accordance with another exemplary embodiment, feet  110  are made of solid material which can be shaped to accommodate non-flat surfaces. For example, feet  110  may be sanded or otherwise shaped to adapt to ridges or humps on the underneath surface and maintain an overlap level decking surface. In another exemplary embodiment, feet  110  are made of detachable segments which can be removed or snapped off to adjust the height of deck tile  100 . In yet another exemplary embodiment, feet  110  are configured to couple to feet extensions which increase the height of deck tile  100 . The feet extensions can be used to accommodate a depression or drop-off in the underneath surface. This ability to shape feet  110  is in contrast to shimming an entire decking surface to adjust to unlevel underneath surfaces. 
         [0027]    In accordance with an exemplary embodiment, different decking material is attached to the top of deck tile  100  using plurality of fastener points  120 . The decking material may include recycled fiber composite, high density foam, wood, plastic, cellular polyvinyl chloride (PVC), stone, ceramic tile, or recycled glass. 
         [0028]    In an exemplary embodiment, fasteners are used to attach the decking material to the top of grid base  101 . The fasteners include at least one of nails, screws, bolts, rivets, adhesive, and the like. In an exemplary embodiment, the fasteners connect the decking material to grid base  101  from the topside. In another exemplary embodiment, the fasteners connect the decking material to grid base  101  from underneath. In yet another exemplary embodiment, deck tile  100  is configured for the fasteners to connect the decking material to grid base  101  from the topside or underneath, and still provide a smooth surface. This may be accomplished by having a dual-beveled connection point in deck tile  100 , as illustrated for example by  FIG. 5 . In one embodiment, grid base  101  may be connected to the decking material by inserting at least one fastener from underneath and further connected to a subframe by inserting at least one fastener from the topside. 
         [0029]    In an exemplary embodiment and with reference to  FIG. 9 , a reducer piece is used to provide a finished edge to the deck tile system. The reducer piece is attached to deck tile  100  at the edge of the overall deck tile system and hangs over the edge in order to visibly cover deck tile  100 . In one embodiment, a deck board is milled and eased to create the reducer piece. The deck tile  100  may be cut as a partial deck tile to fit the necessary dimensions, as shown for example in  FIG. 9 . Furthermore, the reducer piece may be configured for a straight edge or for a corner edge, also as illustrated for example in  FIG. 9 . In an exemplary embodiment, a corner edge reducer comprises two edge reducers, which may have converge at a  45 ° angle, though other alignments are possible as would be understood by one skilled in the art. 
         [0030]    As an additional aspect, a decking tile may include lighting capabilities. In accordance with an exemplary embodiment and with reference to  FIGS. 12   a  and  12   b , a deck tile  100  further comprises a main power hub  201  and power lines connected to each of the sides. In the exemplary embodiment, a power connection post  202  comprises a positive post and a negative post and is located at each of the sides of deck tile  100 . Furthermore, main power hub  201  may be located in the center of deck tile  100  though other locations within deck tile  100  may also be suitable. In an exemplary embodiment, main power hub  201  is a two-level hub having a top level and a bottom level. The top and bottom level facilitate connecting power terminals from all four directions. In one embodiment, wires are used to connect main power hub  201  to the various power connection posts  202  in deck tile  100 . 
         [0031]    Power connection post  202  is configured to electrically couple to another power connection post when decking tiles are connected. This electric coupling is advantageous because the connection can be made without the need to connect wires when assembling the deck in the field. Once one deck tile in an assembled deck grid is connected to a power source, the entire deck grid is connected to power via each power connection post  202 . Moreover, in an exemplary embodiment, deck tile  100  can be oriented in any direction and still make an electrical connection to an adjacent deck tile due to the symmetry of deck tile  100 . As a further advantage, in an exemplary embodiment, only one electrical connection is needed of all the possible electrical connections in order to provide power to main power hub  201 . In other words, if deck tile  100  has four power connection posts  202  and one of power connection posts  202  has a faulty connection, main power hub  201  will still receive power. Approached from a deck tile grid system level, multiple electrical connection failures could occur without consequence. 
         [0032]    In an exemplary embodiment and with reference to  FIG. 13 , a light harness  301  connects to main power hub  201  of deck tile  100 . In one embodiment, light harness  301  comprises LED lights on a string wire with a positive/negative plug that may be replaced as needed. An exemplary light harness  301  may include a single LED light or multiple LED lights, including various colors or configurations. This flexibility allows for multiple lighting designs to be incorporated into the decking design. In an exemplary embodiment, a decking material  302  is designed or drilled in order to allow light harness  301  to be mounted and visibly display the lights. Typically, the lights are flush or slightly recessed with respect to decking material  302 . One benefit of this design is that a single deck tile base design can accommodate many different decking materials  302  to be attached to the surface. In an exemplary embodiment, decking materials  302  can be designed or drilled out to attach to light harness  301 . Moreover, in one embodiment, light harness  301  connects to main power hub  201  of deck tile  100 . The power connection can be at least one of a wire connection, a surface connection, or any other suitable manner of electrically coupling main power hub  201  and light harness  301 . Furthermore, in an exemplary embodiment, main power hub  201  may be electrically coupled to light posts, low voltage landscape features, and the like. 
         [0033]    Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of any or all the claims. As used herein, the terms “includes,” “including,” “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, no element described herein is required for the practice of the invention unless expressly described as “essential” or “critical.”