Patent Abstract:
A structural deck tile system comprising an interlocking deck tile made of a plywood (or similar material) section coated with a mixture of sawdust and polymers such as recycled plastic. Designs and patterns may be embossed or molded into the top surface of the deck tile. The deck tiles have a cut-out notch at each corner and a plurality of interlocking members fit into the notches between adjoining decking tiles to secure them together at the corners. The interlocking members are screwed to the underlying deck joist infrastructure to secure the tiles as one unitary deck tile system, providing structural capacity, and resulting in an economical, aesthetically pleasing, and structurally sound deck with an easier and faster installation. The reduced weight and interlocking fastener system improves the installation process. The endless variety of designs available for the tiles permits individual creative expression in designing exterior decks.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     The present application is a continuation-in-part of U.S. patent application Ser. No. 10/769,290 filed: Jan. 30, 2004, which application derives priority from provisional application Ser. No. 60/444,071 filed: Jan. 30, 2003. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to tile systems for exterior decks, walk paths, and other surfaces that utilize a wood joist frame or functionally similar support structure and, more particularly, to a light weight, composite, structural exterior deck tile system with design and interlocking feature, which simplifies assembly, enforces structural soundness and support and ensures a more uniform and enhanced deck appearance. The present invention is the first structurally sound (spanning 16″ oc) exterior deck tile system comprised of composite materials for residential and commercial use. The deck tile system provides an infinite range of creative designs by embossing and/or molding designs into the top surface of the composite tiles. This technique of creative designs integral to the decking tiles is comparable to the decorative ceramic tile segment of the interior flooring industry. The possible ranges and combinations of pattern, design, texture, and color are endless. This infinite selectivity allows a far greater opportunity for an aesthetically pleasing design and deck installation  
         [0004]     2. Description of the Background  
         [0005]     Exterior decks are typically designed using wood (or similar material) pieces that are milled or manufactured to typical lumber industry sizes such as 5/4×6″ or 2″×6, and a foot or more in length, wherein the wood pieces are arranged end to end and side to side and attached to a joist structure. The wood pieces may be stained or painted to alter the look and the perimeter of the deck may be adorned with lattice work, railing, benches, planters, etc., but the basic look of the floor of the deck provides little variety. The wood decking boards are typically the same size and installed side by side, such that little variety or design potential exists.  
         [0006]     Exterior decks are typically surfaced by wood, plastic, or composite material deck boards. The most common composition is wood. However, currently there are a variety of wood and synthetic deck boards available in various colors. Unfortunately, the limited sizes, colors, installation methods, patterns, structural support requirements, and other inherent properties and/or limitations place constraints on the creativity and design possibilities of building decks.  
         [0007]     Pressure treated pine dominates installed decking lumber. Unfortunately, wood decking has the inherent properties of warp, split, crack, and wane, which properties greatly hinder appearance, usage, and life expectancy. To minimize appearance defects, improve usage, and increase life expectancy, a garden industry of protective coating applications has developed. This necessitates extensive annual maintenance and still does not eliminate the inherent and problematic wood characteristics, which inevitably leads to the replacement of such wood installations. Thus, the “alternative” exterior deck board industry was born in the early 1990&#39;s to provide a low maintenance alternative to wood. Composite (combination of wood saw dust and plastic compounds) and solid plastic decking lumber does not have the “four” characteristics of natural wood (crack, split, wane, warp). As a result, no surface coatings are necessary to combat the negative effects of the “four” characteristics, and termites and rot are not a concern. Additionally installation and usage issues ranging from chemical contact to splinters are not present. The advantages of such decking lumber have yielded tremendous growth rates for this infant sub-contracting industry. There are a number of composite materials used in fabricating decking. One of the first composites introduced was Trex®, a combination of furniture sawdust mixed with polymers. Trex® is formed by combining recycled plastic and sawdust (approximately 50 percent recycled wood, like wood fiber from sawdust and used wooden pallet, and 50 percent recycled plastic materials, from plastic grocery bags and industrial stretch film). These materials are mixed together, and then extruded into boards. The boards are then cut as described. Trex® requires virtually no maintenance, comes with a twenty-five year warranty and does not need to be sealed. Newer composite lumbers include: TimberTech®, Correct Deck™ and EverGrain™. The low maintenance aspects of these composite wood panels have helped them to gain widespread acceptance in recent years for above ground applications such as decks.  
         [0008]     While composite lumber has several advantages over wood, it also has disadvantages that begin with its weaker strength. The plastic portion of the composite compromises the tensile strength of the lumber which limits the distance that the composite board can span from joist to joist as compared to like profile sizes of wood boards. While lumber (depending on the species) can typically span 16″ oc or 24″ oc; composite lumber typically spans 16″ oc and frequently 12″ oc. The additional time and expense of framing joists 12″ oc is costly. Additionally, composite decking is much heavier (up to two times that of wood) and comes in lengths up to 20′ necessitating a physically demanding installation. Yet another critique of composite lumber is that its identically matching profiles to wood yield the very same design and creativity limitations as wood decking.  
         [0009]     Therefore, it would be greatly advantageous to provide a lightweight composite structural exterior deck tile system, using generally sixteen inch square composite tiles with an interlocking feature and joist frame.  
       SUMMARY OF THE INVENTION  
       [0010]     It is, therefore, an object of the present invention to provide a lightweight, composite structural exterior deck tile system with an interlocking feature that provides structural vertical stability, and automatically spaces the decking tiles to give an aesthetically pleasing appearance. It is another of object to provide a structural exterior deck tile system that employs composite tiles.  
         [0011]     It is another object to provide a composite deck tile of 1″-1½″ thickness that eases installation through the use of the auto spacing, hidden, interlocking fastener.  
         [0012]     It is yet another object to provide a light weight structural exterior deck tile system that utilizes deck tiles that are a much lighter weight per square foot than traditional decking, therefore lightening the carrying load and easing the installation difficulty.  
         [0013]     It is still another object to provide a scalable structural exterior deck tile system that facilitates easy replacement of damaged decking tiles.  
         [0014]     It is yet another object to provide a light weight structural exterior deck tile system that provides for endless variations in design, color, patterns, etc.  
         [0015]     It is still another object to provide a lightweight structural exterior deck tile system that employs a joist frame structure for maximum support and stability.  
         [0016]     According to the present invention, the above-described and other objects are accomplished by providing a structural exterior deck tile system comprising a plurality of composite deck tiles formed of a mixture of sawdust and plastic, and having a top surface layer and a bottom frame layer. The top surface layer may be molded or embossed with a pattern or design to provide a unique aesthetic appearance. Each deck tile includes a peripheral groove and is notched at each corner to coordinate with at least one interlocking member that fits into the notches at the corners of adjoining tiles. The tiles are generally sixteen inches square but may be manufactured in various sizes and shapes. The sixteen inch tiles are easily carried and handled. The interlocking members are compression fitted to the corners to secure the tiles together as one unitary deck tile. The structural exterior decking tile system provides an economical composite deck surface that can be built at a similar weight ratio to conventional wood decking boards and one half the weight of typical composite deck boards without compromising structural integrity. Moreover, the deck tile system provides a much improved aesthetic appearance over the current standard exterior deck. An infinite range of creative designs may be employed by embossing and/or molding designs into the top surface of the composite tiles. The possible ranges and combinations of pattern, design, texture, and color are endless. This infinite selectivity allows a far greater opportunity for an aesthetically pleasing design and deck installation. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]     Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which:  
         [0018]      FIG. 1  is a top perspective view of the preferred embodiment of a structural deck tile system according to the present invention.  
         [0019]      FIG. 2  is a bottom perspective view of the structural deck tile system as in  FIG. 1 .  
         [0020]      FIG. 3  is a top view of two composite tiles  20  attached to a joist  35  as in  FIGS. 1-2 .  
         [0021]      FIG. 4  is a top perspective view of a plurality of composite decking tiles  20  with interlocking members  30  as in  FIGS. 1-3 .  
         [0022]      FIG. 5  is a side perspective view of a single deck tile according to the present invention.  
         [0023]      FIG. 6  is a bottom perspective view of the sub frame layer  14  of the tile  20   FIG. 7  is a plan view of a single deck tile according to the present invention.  
         [0024]      FIG. 8  is a 3D perspective view of the interlocking member.  
         [0025]      FIG. 9  is a plan view of the interlocking member of  FIG. 8 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0026]      FIGS. 1 and 2  are top and bottom views, respectively, of a structural exterior deck tile system  2  according to a preferred embodiment of the present invention. The tile system  2  generally comprises a plurality of reinforced deck tiles  20  each formed with particular corner notches and peripheral grooves, and interlocking members  30  that fit into the peripheral grooves at the notches to structurally anchor the deck tiles  20  together in quadrangles, and to anchor the deck tiles  20  to the joist foundation of a deck by a single wood screw  32 . The tiles  20  have reduced mass and thickness, easy self-aligning installation, and collectively form aa structurally superior joist frame for structural stability.  
         [0027]     Each deck tile  20  further comprises a sub frame layer  14  formed of composite ribs  13  (or struts), and a unitary composite layer  12  overlying and joining the ribs  13  of sub frame layer  14  and forming a design surface thereon. The sub frame layer  14  preferably comprises parallel evenly-spaced parallel ribs  13 , and composite layer  12  is integrally formed on top and joins the ribs  13  of sub frame layer  14 . This yields a deck tile  20  that is formed in a generally square tile format. Relative dimensions are important to the present deck tiles  20  to balance their structural soundness with comparatively large size, and so exemplary dimensions will be given herein. The overall dimensions of the illustrated tiles  20  are approximately 3/8″× 15   7 / 8 ″× 15   7 / 8 ″. Composite layer  12  is an approximately 3/8″ thick layer of composite material as conventionally used in fabricated decking, e.g., recycled plastic and sawdust (approximately 50 percent recycled wood, such as wood fiber from sawdust and used wooden pallet, and 50 percent recycled plastic materials, from plastic grocery bags and industrial stretch film). Each rib  13  of the sub frame layer  14  preferably comprises the same material as composite layer  12 , and the entire deck tile  20  inclusive of sub frame layer  14  and composite layer  12  may be integrally molded, such as by injection or compression molding. In either case the molding is preferably completed with a design plate to impart an ornamental imprint-design on composite layer  12 , thereby giving a true carved “tile” appearance which has heretofore not been available for outdoor deck structures. This flexibility in the appearance of the deck tiles  20  provides for a multitude of possibilities in design, pattern, shape and color, thus creating a decorative and aesthetically pleasing effect, previously unknown in the decking industry. The spaced ribbed composite design of the sub frame layer  14  allows the resulting deck tile  20  to be structurally sound and yet capable of spanning 16″ O.C. (on-center).  
         [0028]     In addition, each tile  20  is formed with a ⅛″ height× 3/8″ deep×1″ length cut-out notch  22  at each corner of the deck tile  20  (approximately ⅓ of the way from the bottom of the decking tile  2 ). Cut-outs  22  help to allow a quadrangle of deck tiles  20  to be secured together at the edges by a plastic interlocking member  30  and a wood screw  32 . Quadrangles of deck tiles  20  are successively secured at the edges over the open joists  35  of an otherwise standard deck infrastructure until the deck is completely surfaced with deck tiles  20 . The combination of reduced mass and thickness, plus easy self-aligning installation and joist frame, greatly reduces assembly time and complexity, as well as the weight of the final deck, while maintaining structural stability.  
         [0029]      FIG. 3  is a top view of two composite tiles  20  attached to an existing deck joist  35  by two interlocking members  30 . The interlocking members  30  are cross-shaped structures that fit down into the cut-out notch  22  at the corners of the tiles  20 . The arms of the interlocking members  30  fit into slots defined in the sides of the tiles  20  to anchor them. Thus, both the interlocking members  30  and tiles  20  may be secured with standard wood screws  32 .  
         [0030]      FIG. 4  is a top perspective view of a plurality of composite deck tiles  20  assembled together, with fastener  30  shown in dotted lines. The interlocking feature of interlocking member  30  gives the ability to fasten the entire deck tile system  2  around the deck infrastructure from edge-to-edge. If a deck tile  20  is ever damaged, the discrete fastener design facilitates easy replacement. One skilled in the art will appreciate that the foregoing deck tiles  20  may be provided in other forms including square and rectangular sizes ranging from 12″×12″ to 24″×24″. Given an array of composite deck tiles  20  of differing dimensions, it becomes a simple task to compile an entire deck surface having a unique aesthetic appearance.  
         [0031]      FIG. 5  is a side perspective view of the single deck tile  20  of  FIG. 4  illustrating the ribs  13  extending downward from the composite surface  12 . The ribs  13  are generally ⅜ inches thick by one inch in height. The ribs  13  are spaced every 3″ OC and run in both directions (intersecting to form a matrix), thereby allowing the tile  20  to placed in any direction to meet the surface design&#39;s requirements. The outermost ribs  13  form a rectilinear boundary  13 B that circumscribes the inner ribs  13 . An upper groove  25  runs around this boundary  13 B, groove  25  being approximately ¼″×¼″×¼″. The groove  25  is adapted for compression-fit insertion of a section of the interlocking fastener  30  (as described more fully below in regard to  FIGS. 8 and 9 , the interlocking member  30  comprises three vertical sections: a base section  36 , a leg section  37 , and a raised section  38 , the latter of which fits inside groove  25 ).  
         [0032]     In addition to the upper groove  25 , each corner of the tile  20  along the outer boundary  13 B is formed with a recessed notch  22  measuring ⅛″ high by ⅜″ leg depth by 1.5″ length. This recessed notch  22  receives the lower base  36  of the interlocking fastener  30  (lower base  36 , leg section  37 , and raised section  38  are described more fully below in regard to  FIGS. 8 and 9 , and the base  36  fits inside groove  25 ).  
         [0033]      FIG. 6  is a bottom perspective view of the sub frame layer  14  of the tile  20 , further illustrating the ribs  13  extending downward from the composite surface  12  and the layout of recessed notches  22 .  
         [0034]      FIG. 7  is a plan view of a single deck tile  20  according to the present invention. In the illustrated embodiment, the deck tile  20  is approximately sixteen (15.875′) by sixteen (15.845″) inches square, and may be any color with any design [DESIGN] molded or embossed in the top surface of the tile  20 . Thus, the collective arrangement of the tiles  20  creates an over-all pleasing aesthetic appearance. The deck tile system provides an infinite range of creative designs by embossing, injection molding, and/or compression molding designs into the top surface of the composite tiles. As with ceramic tiles, the possible ranges and combinations of pattern, design, texture, and color are endless. The deck owner is no longer restricted by limited choices in color and accessories, where one deck doesn&#39;t look much different than another. With the present invention, an individual deck owner may have her own unique design.  
         [0035]      FIG. 8  is a 3-D perspective view of the interlocking member  30  of  FIG. 6 . The total height of the interlocking member  30  is approximately one inch, and there are three distinct sections running vertically from a lower base section  36 , a leg section  37 , and a raised section  38 . Both the lower base section  36  and raised section  38  are in the shape of a Greek cross (with cruciform arms), the lower base section  36  being a larger cross relative to raised section  38 . In use, each of the arms of the base section  36  of the interlocking member  30  fits into a corresponding recessed notch  22  in a quadrangle of four arranged tiles  20 , and each of the arms of the raised section  38  compression fits into each corresponding groove  25  of those four tiles  20  to form a friction fit.  
         [0036]      FIG. 9  is a plan view of the interlocking member  30  according to the present invention. The interlocking member  30  is preferably formed of high-density polyethylene, or like material, and is defined with a pre-tapped screw hole  33  in each arm of the cross of the base section  36 . Again, each arm of the raised section  38  of the interlocking member  30  is friction/compression fit into the groove  25  of each of four deck tiles  20 , and interlocking member  30  is then screwed to the underlying supporting joist  35  via four wood screws  32 , one through each of the screw holes  33  in each arm of the base section  36  of the interlocking member  30 . The base section  36  secures into the recessed notch  22  of each tile  20  at the corner allowing four tiles to be fastened with one interlocking fastener  30 .  
         [0037]     It should now be apparent that the foregoing invention provides a uniform and decorative appearance to decks, utilizes a joist structural frame to provide maximum support, and automatically spaces the deck tiles to give an aesthetically pleasing deck structure. The “hidden fastener” interlocking feature allows a much easier installation and uniform appearance. The deck tile system provides an infinite range of creative designs by embossing and/or molding designs into the top surface of the composite tiles. This technique of creative designs integral to the deck tiles is comparable to the decorative ceramic tile segment of the interior flooring industry. The possible ranges and combinations of pattern, design, texture, and color are endless, and size of the tiles enables the installer to easily carry and handle them. This presents a far greater opportunity for an aesthetically pleasing design and deck installation. Moreover, the mechanism to attach the interlocking tiles to a joist frame provides maximum structural support unlike any other non-standard deck tile system can provide.  
         [0038]     Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth in the appended claims.

Technology Classification (CPC): 4