U.S. patent application number 11/054204 was filed with the patent office on 2005-09-08 for modular decking tile.
Invention is credited to Smart, Gregory James, Smart, Lyndy Jane, Wootton, Darryl John.
Application Number | 20050193675 11/054204 |
Document ID | / |
Family ID | 27809898 |
Filed Date | 2005-09-08 |
United States Patent
Application |
20050193675 |
Kind Code |
A1 |
Smart, Gregory James ; et
al. |
September 8, 2005 |
Modular decking tile
Abstract
A tile for forming a modular deck with like-configured tiles,
the tile having a web having a planar polygonal upper surface and a
lower surface, a web strengthening structure on said lower surface,
and a plurality of peripheral edges, where at least one of the
edges includes a male connecting portion having a lateral tongue
extending from the peripheral edge, and at least one of the edges
includes a female connecting portion defining a lateral recess in
the peripheral edge. In one embodiment, at least three of the
peripheral edges include either of the male connecting portions or
the female connecting portions.
Inventors: |
Smart, Gregory James;
(Balwyn North, AU) ; Smart, Lyndy Jane; (Balwyn
North, AU) ; Wootton, Darryl John; (Moorabin,
AU) |
Correspondence
Address: |
WOODCOCK WASHBURN LLP
ONE LIBERTY PLACE, 46TH FLOOR
1650 MARKET STREET
PHILADELPHIA
PA
19103
US
|
Family ID: |
27809898 |
Appl. No.: |
11/054204 |
Filed: |
February 9, 2005 |
Current U.S.
Class: |
52/578 |
Current CPC
Class: |
E01C 9/08 20130101; E04B
5/026 20130101; E01C 5/20 20130101; E01C 5/16 20130101; E04B 5/02
20130101; E04F 2201/096 20130101; E04F 2201/091 20130101; E04F
15/06 20130101; E04F 15/02194 20130101; E04F 2201/0505 20130101;
E04F 15/105 20130101 |
Class at
Publication: |
052/578 |
International
Class: |
E04B 002/00 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 8, 2003 |
WO |
PCT/AU03/01010 |
Aug 9, 2002 |
AU |
AU 2002950813 |
Claims
What is claimed:
1. A tile for forming a modular deck with like-configured tiles,
the tile having: a web having a planar polygonal upper surface and
a lower surface; a web strengthening structure on said lower
surface; and a plurality of peripheral edges wherein at least one
of said edges includes a male connecting portion comprising a
lateral tongue extending from said peripheral edges, and at least
one of said edges includes a female connecting portion defining a
lateral recess in said peripheral edge, whereby at least three of
said peripheral edges include either of said male connecting
portions or female connecting portions and such that the male
connecting portion of one tile may be located into the lateral
recess of the female connecting portion of an adjacent tile by
lateral relative sliding movement of said tiles.
2. The tile of claim 1, wherein said web strengthening structure
comprises a plurality of reinforcing webs perpendicular to the
plane of the upper surface.
3. The tile of claim 1, wherein said tile has one or more severing
lines.
4. The tile of claim 3, wherein at least one of said severing lines
extends between adjacent corners of said polygonal shape.
5. The tile according of claim 3, wherein at least one of said
severing lines extends between opposite corners of said polygonal
shape.
6. The tile of claim 3, wherein a plurality of reinforcing webs are
provided proximate to and substantially parallel to said severing
line or lines.
7. The tile of claim 1, wherein said male connecting portion
comprises a lateral tongue which extends laterally from and along a
central part of said peripheral edge and is substantially
perpendicular to the plane of the upper surface.
8. The tile of claim 7, wherein said male connecting portion
includes a cutaway section which extends into the upper surface
beyond the line of said edge to create a recess in the upper
surface.
9. The tile of claim 1, wherein said female connecting portion
comprises a lateral recess in said peripheral edge extending into
the tile.
10. The tile of claim 9, wherein said female connecting portion
includes an upper flange and a lower flange which extend beyond the
edge of said tile and the recess is located between said upper and
lower flanges.
11. The tile of claim 1, wherein said upper surface is hexagonal in
shape.
12. The tile of claim 11, wherein three peripheral edges have male
connecting portions thereon and three peripheral edges have female
connecting portions thereon, and wherein said male and female
connecting portions are alternately spaced about said tile.
13. The tile of claim 1, wherein each male and female connecting
portion includes a bore therethrough in a position such that when
the male connecting portion of one tile is properly inserted into
the female connecting portion of an adjacent identical tile, the
bores are coaxial so as to allow insertion of a securing rod
therethrough.
14. The tile of claim 13, wherein each female connecting portion
includes a recess proximate to said bore adapted to receive the
head of said securing rod.
15. The tile of claim 1, wherein said tile includes a bore in the
center of said upper surface.
16. The tile of claim 15, wherein said tile includes a recess
proximate to said bore in the center of said upper surface adapted
to receive the head of said securing rod.
17. A modular deck comprising a plurality of like-configured tiles,
the tiles including: a web having a planar polygonal upper surface
and a lower surface; a web strengthening structure on said lower
surface; and a plurality of peripheral edges, wherein at least one
of said edges includes a male connecting portion comprising a
lateral tongue extending from said peripheral edges, and at least
one of said edges includes a female connecting portion defining a
lateral recess in said peripheral edge, the male connecting
portions being inserted into female connecting portions of adjacent
tiles such that tiles resist lateral, upward and downward movement
relative to adjacent tile; whereby at least three of said
peripheral edges include either of said male connecting portions or
female connecting portions and such that the male connecting
portion of one tile may be located into the lateral recess of the
female connecting portion of an adjacent tile by lateral relative
sliding movement of said tiles;
18. The modular deck of claim 17, wherein a plurality of securing
rods are located through the bores of joined male and female
connecting portions, the securing rods having heads located in
recesses in the female connecting portions.
19. The modular deck of claim 18, wherein there is provided a first
layer and a second layer of tiles, wherein, in each layer, male
connecting portions are inserted into the female connecting
portions of adjacent tiles, the edges of the first layer of tiles
being offset from the edges of the second layer of tiles, and bores
of tiles in the first layer are coaxial with bores of the second
layer so that a securing rod may be passed through both layers to
secure the deck in position.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of PCT/AU2003/001010,
filed Aug. 8, 2003, which claims priority to AU 2002950813, filed
Aug. 9, 2002, the disclosures of which are incorporated by
reference herein in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to a modular decking tile, and
temporary decking made from modular decking tiles.
BACKGROUND OF THE INVENTION
[0003] Exploration for mineral resources such as natural gas and
oil often takes place in regions remote from civilization. Such
exploration sites are often located in remote jungles in tropical
climates of high rainfall, in mountainous areas, or in areas of
particular environmental sensitivity. When a mining organization
selects a site for drilling, one of the initial tasks is to clear a
working area of native vegetation, and to construct a working
platform on top of the cleared earth on which equipment, buildings
and drilling hardware can be assembled. The conventional foundation
for this platform requires transportation of gravel or concrete and
in many cases timber felled for the cleared site, from the
surrounding forests. In many cases the working platform area is of
considerable size, so large amounts of timber are required. Not
only is this process labor intensive and high risk, it is also
destructive to a broad perimeter of vegetation surrounding the
actual working area and can be regarded as an environmentally
unsound practice. Once drilling operations cease, the cut timber is
not of economic value so it is left in situ and gravel and timber
are required to be excavated and removed from the location. Despite
any restoration works to the area, the native flora is likely to
take decades to regenerate and recover.
[0004] In mining locations where there is no local supply of forest
timber from which to make a suitable working platform, companies
have been known to airlift in loads of gravel for foundations,
clearly at considerable expense. Again, although material is
generally not recovered for re-use after the site is abandoned, it
may need to be excavated and removed.
[0005] Mining operations place high demands on the working
platform. The platform must be stable when heavy machinery is
driven over it. It must be capable of stabilizing the earth upon
which it is laid because mining sites are frequently in high
rainfall areas where erosion can otherwise occur. These platforms
are often required to be used as helicopter landing sites, and must
be capable of being safely secured in place so that when
helicopters are landing or taking off, the turbulent rotor downwash
does not dislodge parts of the platform which could otherwise fly
out to injure personnel or damage the aircraft.
[0006] Accordingly, there is a need for a modular platform or
decking with inherent mechanical attributes which can be installed
at a desired site which may be accessible only by aircraft, can be
assembled in a wide variety of configurations, can be safely
secured to the ground to withstand high loads, traffic and wind
forces such as helicopter rotor downwash, and which can be easily
dismantled and removed for reuse. There is also a need for modular
decking tiles that can easily be cut into alternative shapes yet
retain its load bearing strength.
SUMMARY OF THE INVENTION
[0007] The present invention provides a modular decking tile and
modular decking formed from such tiles that satisfy one or more of
the above requirements. It will be convenient to refer to the
invention in relation to use for oil and gas, mining and remote
area exploration applications, although it will be appreciated that
the invention may have wider application where a modular heavy-duty
temporary ground cover is required.
[0008] According to one aspect of the present invention there is
provided a tile for forming a modular deck with like-configured
tiles, where the tile may have a planar polygonal upper surface and
a lower surface, a web strengthening structure on said lower
surface and a plurality of peripheral edges, where at least one of
said edges includes a male connecting portion including a lateral
tongue extending from said peripheral edge, and at least one of
said edges includes a female connecting portion defining a lateral
recess in said peripheral edge, whereby at least three of said
peripheral edges include either of said male connecting portions or
female connecting portions and such that the male connecting
portion of one tile may be located into the lateral recess of the
female connecting portion of an adjacent tile by lateral relative
sliding movement of said tiles.
[0009] The tile may have a planar polygonal upper surface. The
upper surface forms the surface of the deck that is subjected to
downward and lateral forces from traffic including pedestrian and
vehicular traffic when in use. The upper surface may include
friction-enhancing means such as a textured or roughened surface
treatment, and/or a plurality of raised lugs such as a chequerplate
pattern so as to reduce the risk of slipping on the upper surface.
The upper surface may be a regular polygonal shape such as a
triangle, square, pentagon or octagon, but preferably is hexagonal
in shape. It is considered that a hexagonal shape allows the
greatest degree of versatility in deck configuration and also
provides lo optimal rigidity and interfile connection to create the
deck structure. This is because each tile within the deck structure
is held in place by six adjacent tiles.
[0010] The web is preferably a continuous web that doesn't allow
passage of water or air from the upper surface to the lower
surface, although it may optionally be of a mesh configuration or
have openings for drainage or ventilation if desired.
[0011] The lower surface of the web has a web strengthening and
reinforcing structure for mechanical integrity to enable the web to
withstand downward and lateral loads. The reinforcing web may be a
plurality of webs perpendicular to the plane of the upper surface.
Preferably the webs of the reinforcing structure are made from the
same material as the web and are formed integrally therewith. The
reinforcing webs may form box-like or triangular reinforcing
structures, triangular reinforcing structures or circular
reinforcing structures or combinations of these. In a preferred
embodiment, the tile has one or more severing lines, preferably
which run between opposite and or adjacent corners of the polygonal
shape. These are so that the tile can be cut into shapes different
from the shape of a full tile so irregular decking arrangements can
be made. Preferably a plurality of reinforcing webs are provided
proximate to and substantially parallel with such severing lines
although other reinforcing webs may be provided which do lie on
said severing lines which would be cut if the tile is cut along
that severing line. In one embodiment, such webs are provided
alternately on either side of such severing lines.
[0012] The tile may have a plurality of peripheral edges that abut
corresponding edges of complementary tiles when in use. Preferably
the edges are substantially linear except for the connection
portions, which are described below. The edges preferably each have
a continuous edge face, which is perpendicular or slightly angular
to the plane of the upper surface.
[0013] In one embodiment, at least one of the edges includes a male
connecting portion that comprises a lateral tongue. The tongue may
extend from and along a central part of the peripheral edge
laterally and substantially perpendicular to the plane of the
peripheral edge. Most preferably the male connecting portion
includes a cutaway section that extends into the upper surface
beyond the line of the edge so that a recess exists in the upper
surface. This is so that the tongue does not just extend from the
edge of the tile, but extends from a region within the edges of the
tile.
[0014] In one embodiment, at least one of the edges includes a
female connecting portion which defines a lateral recess in the
peripheral edge. Preferably the female connecting portion consists
of an upper flange and a lower flange that extend beyond the edge
and the recess between the upper and lower flanges which extends
into the tile beyond the edge of the tile.
[0015] Preferably the tile is hexagonal and three of the six edges
have a male connecting portion and each of the three other edges
has a female connecting portion. Preferably the male and female
connecting portions are equally and alternately spaced around the
edges of the tile (i.e., each edge with a female connecting portion
has on either side an edge with a male connecting portion, and vice
versa, so that going around the tile the edges have male, then
female, then male, then female, etc connection portions). The male
and female connecting portions are of complementary shape so that
the male portion may be snugly accommodated in the female portion
of an adjacent tile with little relative movement possible between
the tiles when so joined. Each of the male and female connecting
portions may include a bore in a position where the bores of joined
male and female portions are coaxial so as to allow insertion of a
securing rod therethrough. Female connecting portions preferably
include a recess proximate said bore adapted to receive a head of
said securing rod so that the head of the securing rod can be
recessed below the plane of said upper surface. More preferably the
recess is located in the upper flange of the female connecting
portion.
[0016] Additionally tiles may include a bore in a central region or
any other region of the upper surface through which a securing rod
may be passed. Such a bore preferably has a recess adapted to
receive the head of a securing rod, and may have additional
recesses proximate the first recess to facilitate removal of a
securing rod.
[0017] In another aspect of the invention there is provided a
modular deck comprising a plurality of like-configured modular
tiles as previously defined, wherein male connecting portions of
tiles are inserted into female connecting portions of adjacent
tiles such that tiles resist lateral, upward and downward movement
relative to adjacent tiles. In yet another preferred embodiment the
modular decking may further include a plurality of securing rods
located through the bores of joined male and female connecting
portions, and wherein the securing rods have heads located in
recesses in the female connecting portions. In another aspect of
the invention there may be provided a modular deck as previously
defined consisting of a first layer of assembled tiles and a second
layer of assembled tiles, wherein the edges of the first layer of
tiles are offset from the edges of the second layer of tiles and
where bores of tiles in the first layer are coaxial with bores of
the second layer so that a securing rod may be passed through both
layers of tiles to secure said deck in position. Additionally, any
number of layers of tiles can be achieved so that a securing rod
can be passed through all layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] It will now be convenient to describe the invention with
particular reference to the preferred embodiments. It will be
appreciated that the drawings related to a preferred embodiment
only and are not to be taken as limiting the invention.
[0019] FIG. 1 shows a top view of a modular decking tile according
to one embodiment of the present invention;
[0020] FIG. 2 shows a bottom view of a modular decking tile
according to the present invention;
[0021] FIG. 3 shows a perspective view of a female connector
portion of the present invention;
[0022] FIG. 4 shows a perspective view of a male-connector portion
of the present invention;
[0023] FIG. 5 shows a top plan of a modular deck made up from two
layers of modular decking tiles of the present invention; and
[0024] FIG. 6 shows a perspective view of a fixing peg of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In FIG. 1, modular decking tile 1 has a planar hexagonal
upper surface 3 bearing a pattern of raised friction lugs 5 to
provide grip to upper surface 3. Lugs 5 are shown in a chequer
plate configuration designed to ensure that wheels of vehicles or
footwear of pedestrian traffic does not slip on upper surface 3,
particularly when upper surface 3 is wet or muddy. The surface area
of upper surface 3 may be up to approximately 3 m.sup.2 although
smaller or larger versions may be made if desired. Peripheral edges
7, 7a and & 7b each have a female connector portion 9, 9a and
9b typically shown in more detail in FIG. 3.
[0026] Peripheral edges 11, 11a and 11b each have male connector
portions 13, 13a and 13b typically shown in more detail in FIG.
4.
[0027] Upper surface 3 has recessed lines 15 and 15a which are
reduced slightly below the plane of upper surface 3. Recessed lines
15 and 15a may accommodate an adhesive marking tape (not shown) for
clearly outlining desired areas of a decking made up of modular
decking tiles 1, for example. The marking tape may define a landing
zone for helicopters, or a walkway or vehicle pathway bordered by
tape or other marking means in the recessed lines 15 and 15a of one
or more modular decking tiles 1.
[0028] Securing openings are provided in various locations through
the modular decking tile. Securing openings 16, 16a and 16b are
shown in female connector portions 9, 9a and 9b and securing
openings 18, 18a and 18b are shown in male connector portions 13,
13 and 13b. Central securing opening 20 is shown in the center of
modular decking tile 1 and has a head recess 22. The securing
openings are adapted to receive a fixing peg shown in FIG. 6.
[0029] In FIG. 2, the underside of modular decking tile 1 is shown.
Under-side 17 comprises a multitude of structural reinforcing web
members typically shown as 19, 19a and 19b. These webs are
perpendicular to the plane of upper surface 3 and give the modular
decking tile 1 structural and torsional rigidity and load bearing
capability for loads applied to upper surface 3. Webs are generally
lo arranged in a square or rectangular arrangement shown typically
as 21 and 21a, with additional webs forming concentric circular
reinforcing structures 23, 23a and 23b.
[0030] Two severing lines 25 and 25a are shown where webs are
positioned and aligned on either side of these lines. This is so
that the modular decking tile 1 can easily be cut or sawn along
either of severing lines 25 or 25a to form alternative polygonal
shapes. These may be required to fill certain spaces in a modular
deck that cannot be filled with a full sized decking tile,
particularly along edges or corners of such a deck. The severing
line 25 extends between opposite corners 29 and 29a and severing
line 25a extends between adjacent corners 27 and 27a. Webs falling
along the severing lines 25 and 25a are preferably spaced less than
about 20 mm from their respective severing line. This is so that if
the modular decking tile is cut, the ingress of water, soil,
insects, or other things into recesses created by cutting the
modular decking tile are minimized at the same time maintaining the
strength and integrity of the tile even though the tile has been
cut.
[0031] In FIG. 3 female connector 9 consists of an upper flange 31,
which extends from and is continuous with upper surface 3 and a
lower flange 33 of corresponding shape to upper flange 31. Upper
flange 31 and lower flange 33 define a recess 35 that receives a
male portion, which is shown in more detail in FIG. 4. Recess 35
extends into the body of modular decking tile 1 at least as deep as
the extent to which flanges 31 and 33 extend beyond edge 37.
[0032] Upper flange 31 includes a pair of access slots 39 and 39a
to assist with peg removal, a fixing peg head recess 41 and a
securing opening 18, and lower flange 33 includes a securing
opening (not shown) coaxial with securing opening 18. Access slots
39 and 39a are provided to allow a tool to be hooked underneath the
head of a "T" shaped fixing peg so as to withdraw the fixing peg
from securing opening 18. The head of the fixing head is located
within the confines of head recess 41 so that it does not project
into upper surface 3 to present a hazard. Recess 35 may be offset
from the centerline of edge 37 (i.e., upper flange 31 may be
thicker than lower flange 33).
[0033] In FIG. 4 male connector portion 13 consists of a tongue 43
which projects beyond edge 45. Tongue 43 is of a complementary
shape to recess 35 and is of slightly smaller dimensions so it can
be snugly located within recess 35. Male connector portion also
includes cut away region 47 of upper surface 3 and cut away region
50 of under-side 17.
[0034] The design of the connector portions shown in FIGS. 3 and 4
is such that when the female connector portion of one modular
decking tile is coupled with the male connector portion of another
modular decking tile, the mating engagement provides for a very
secure fit which minimizes the risk of progressive loosening and
separation of the joined tiles, particularly after repetitive
traffic movement over the modular deck. Male connector portion 13
also includes a securing opening 49 in a position corresponding to
that in the female connector portion of FIG. 3. This is so that a
fixing peg can be inserted through the securing openings of both
male and female connector portions when assembled to more securely
fix the decking in position.
[0035] In FIG. 5 three upper tiles 51, 51a and 51b are shown laid
in an offset arrangement over four lower tiles 53, 53a, 53b and
53c. This offset arrangement provides a highly stable platform with
high load bearing capacity. Fixing pegs, typically shown as 55, are
provided where male and female connector portions of upper tiles 51
and 51b are joined, which is in register with where male and female
connector portions of lower tiles 53 and 53b are joined. The single
fixing peg thus secures four tiles into position in three ways.
First it secures all four tiles in position relative to the ground
on which they lie. Secondly, it secures each pair of tiles whose
male and female portions are coupled relative to each other.
Thirdly, it secures the upper layer relative to the lower layer to
prevent the upper layer from sliding over the lower layer.
[0036] Fixing pegs, typically shown as 55a, are provided where the
center of a tile (51b) in the upper layer is in register with where
the male and female connector portions of tiles 53c and 53b are
joined. The resultant platform has an extremely high degree of
stability to resist the downward loads, lateral shearing and
uplifting forces which are encountered while in use.
[0037] In FIG. 6, fixing peg 56 is substantially "t" shaped and
consists of an elongate shank 57 and a head 59 connected thereto.
Elongate shank 57 is of suitable strength to be driven into the
ground to secure decking tiles in position and is of a diameter
slightly less than the diameter of openings 16, 18 and 20, so it
can easily be inserted through them. Head 59 is of suitable
strength and is affixed to the shank 57 so as to withstand
hammering to drive shank into the ground and being pulled to
withdraw the fixing peg when the modular deck is dismantled. Head
59 is of a size and shape to enable it to fit within head recess 22
or 41, so that it does not protrude beyond the top of the deck
surface.
[0038] To assemble a modular decking of the present invention on a
cleared ground, a pair of modular decking tiles are positioned so
that the male connector portion of one decking tile is positioned
close to the female connector portion of an adjacent decking tile.
The male and female connector portions are then fully engaged so
that the cooperation of the two connector portions prevents both
lateral and vertical relative movement of the two modular decking
tiles along their abutting edge. Further decking tiles are added to
those already assembled so as to build up the desired decking
area.
[0039] If the decking arrangement requires a space to be filled
into which a whole modular decking tile will not fit, a decking
tile may be cut by suitable means along either or both of the
cutting lines described above. The cut piece is then fitted into
the decking in the same manner as for whole modular decking
tiles.
[0040] If only light or moderate loads and forces are likely to be
applied to the modular decking, a single layer of modular decking
tiles may be adequate. If high loads and forces are likely, a
second layer or multiple layers of modular decking tiles may be
assembled on top of the first layer. Preferably this is done in an
offset manner as shown in FIG. 5. In this configuration, the center
of a modular decking tile in the upper layer is positioned directly
above the joined male and female connector portions of the
underlying modular tiles.
[0041] Fixing pegs may be used to additionally secure the modular
decking into position if desired. Fixing pegs may be inserted
through either center openings in modular tiles or through the
openings in joined male and female connector portions and hammered
home so that the head of the peg is located in the recess at the
opening. This latter arrangement ensures that the male and female
connector portions stay engaged and greatly enhances the structural
integrity of the modular decking. It will not generally be
necessary to insert a fixing peg through each pair of joined
connector portions because when other adjacent modular decking
tiles are assembled, they will tend to resist movement of other
tiles in the array. However, it may be desirable to use more fixing
pegs in high traffic areas to further reduce the risk of movement
of the modular tiles.
[0042] Disassembly of the modular deck is essentially the reverse
of assembly. First, a fixing peg removal tool is used. This tool
has one or preferably two prongs which are inserted into slots
adjacent the head recess and the tool is hooked under the head of
the fixing peg. The fixing peg can then be drawn vertically from
the ground into which it is driven and removed from the openings.
Adjacent modular tiles are then separated one by one, commencing at
the periphery of the modular deck. The individual tiles are then
optionally cleaned, stacked and transported for reuse.
[0043] The modular decking tiles may be made from any suitable
material, for example thermoplastic polymers such as virgin or
recycled polyethylene or polypropylene, with or without various
stabilizers and/or modifiers, or metals such as aluminum or steel,
and may be made by any suitable method such as injection molding,
rotary molding or casting. Preferably the modular decking tiles are
made from polyethylene, although depending on the demands of the
modular decking, modular tiles of different materials but of
complementary dimensions may be employed together. Tiles may be
provided in a range of colors so that selected areas of decking may
be colored. For example, red tiles may be used in high danger areas
to warn workers of hazard areas.
[0044] Finally, the decking tiles may be made in any sizes suitable
for easy handling and rapid installation.
[0045] It is to be understood that various modifications, additions
and/or alterations may be made to the arrangements previously
described without departing from the ambit of the present
invention.
* * * * *