U.S. patent application number 11/669586 was filed with the patent office on 2007-08-23 for outdoor flooring, deck and patio surface system and method.
Invention is credited to David M. Busby, Philip J. Busby.
Application Number | 20070193163 11/669586 |
Document ID | / |
Family ID | 38426715 |
Filed Date | 2007-08-23 |
United States Patent
Application |
20070193163 |
Kind Code |
A1 |
Busby; David M. ; et
al. |
August 23, 2007 |
OUTDOOR FLOORING, DECK AND PATIO SURFACE SYSTEM AND METHOD
Abstract
A system and method for providing an outdoor flooring such as a
lightweight deck surface, employs a fiber reinforced polymer
structural panel with plural grid openings therein. A fastener is
driven into selected openings to enable the panel to be secured to
a deck frame. A surfacing material, such as a quarried stone, is
attached to the top of the panel, providing a stone deck surface
without requiring substantial structural support.
Inventors: |
Busby; David M.; (Hillsboro,
OR) ; Busby; Philip J.; (Hillsboro, OR) |
Correspondence
Address: |
PATENTTM.US
P. O. BOX 82788
PORTLAND
OR
97282-0788
US
|
Family ID: |
38426715 |
Appl. No.: |
11/669586 |
Filed: |
January 31, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60764190 |
Jan 31, 2006 |
|
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Current U.S.
Class: |
52/389 |
Current CPC
Class: |
E04F 2015/0205 20130101;
E04F 15/0215 20130101; E04F 15/08 20130101; E04F 15/02194 20130101;
E04F 2015/02111 20130101 |
Class at
Publication: |
052/389 |
International
Class: |
E04F 13/08 20060101
E04F013/08 |
Claims
1. An outdoor flooring system system, comprising: a composite
surface, said composite surface comprising a structural panel
member adapted for mounting as a base framework; and a surface
material adapted for attachment to a top surface of the structural
panel to provide a flooring surface.
2. The system according to claim 1, wherein said structural panel
member comprises a fiber reinforced polymer panel.
3. The system according to claim 2, wherein said structural panel
member is formed with plural openings therein.
4. The system according to claim 3, wherein said plural openings
form a grid pattern.
5. The system according to claim 3, wherein ones of said plural
openings are substantially rectangular in shape.
6. The system according to claim 3, wherein ones of said plural
openings are substantially square in shape.
7. The system according to claim 1, wherein said surface material
comprises a stone.
8. The system according to claim 7, wherein said stone comprises a
quarried stone.
9. The system according to claim 1, wherein said surface material
is selected from the group consisting of tile, brick, concrete or
stone pavers.
10. The system according to claim 1, further comprising an adhesive
between said structural panel member and said surface material for
adhering said surface material to said structural panel member.
11. The system according to claim 10, wherein said adhesive
comprises a flexible layer having a first face for adhering to said
structural panel and a second face for adhering to said surface
material, said first and second faces including a pressure
sensitive contact adhesive thereon.
12. A method of providing a flooring surface, comprising the steps
of: mounting a structural panel member to a framework; and
attaching a surface material to a top surface of the structural
panel to provide a flooring surface.
13. The method according to claim 12, wherein said structural panel
member comprises a fiber reinforced polymer panel.
14. The method according to claim 13, wherein said structural panel
member is formed with plural openings therein.
15. The method according to claim 14, wherein said plural openings
form a grid pattern.
16. The method according to claim 14, wherein ones of said plural
openings are substantially rectangular in shape.
17. The method according to claim 14, wherein ones of said plural
openings are substantially square in shape.
18. The method according to claim 12, wherein said surface material
comprises a stone.
19. The method according to claim 18, wherein said stone comprises
a quarried stone.
20. The method according to claim 12, wherein said attaching
comprises providing a flexible sheet membrane with pressure
sensitive adhesive thereon, and positioning said flexible sheet
membrane between said structural panel and said surface
material.
21. A fastener for use in securing two elements, comprising: a top
surface having plural tooth members on at least two opposite sides
thereof; at least two downwardly extending leg members, on opposite
sides, having outwardly extending teeth at a distal end thereof.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to outdoor flooring, surfaces for
decks, patios and the like, and more particularly, to a decking
system and method for enabling use of surface materials that would
ordinarily lack suitable structural features to accommodate deck or
patio applications.
[0002] Stone walkway and step surfaces are frequently used at homes
and businesses, as the appearance is attractive and enjoyed by
many. Walkway and step stones are typically rather thick, to
provide sufficient structural properties to support weight
necessary in walkway and step use. As such, given the weight of
stone, elevated deck surfaces such as for home decks, do not employ
stone surfaces, as the weight of the stone requires substantially
structural support beyond what is typically employed for deck
construction.
SUMMARY OF THE INVENTION
[0003] In accordance with the invention, a deck and patio surface
system comprises a fiber reinforced structural panel employed as a
substrate, a mounting fastener for enabling the panel to be secured
to a deck, patio, or the like, and a surfacing material bonded or
otherwise attached to the structural panel.
[0004] Accordingly, it is an object of the present invention to
provide an improved deck system to enable use of stone surface in
above-ground deck applications.
[0005] It is a further object of the present invention to provide
an improved system for deck or patio applications to allow use of
surface material not normally by itself having sufficient
structural properties for such use.
[0006] It is yet another object of the present invention to provide
an improved method for providing a deck surface.
[0007] Another object of the present invention is to provide a deck
or patio system adapted for use over waterproofed living space
without requiring penetration of the waterproof membrane.
[0008] It is still another object of the present invention to
provide a system and method for providing a new surface over an
existing damaged patio surface.
[0009] The subject matter of the present invention is particularly
pointed out and distinctly claimed in the concluding portion of
this specification. However, both the organization and method of
operation, together with further advantages and objects thereof,
may best be understood by reference to the following description
taken in connection with accompanying drawings wherein like
reference characters refer to like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is an exploded perspective view of a portion of the
system according to the invention;
[0011] FIG. 2 is a top view of the fastener of FIG. 1, during an
initial forming phase;
[0012] FIG. 3 is a top view of the fastener of FIG. 2 when formed
to final shape;
[0013] FIG. 4 is a sectional view of the fastener of FIG. 3 taken
along line 4-4 of FIG. 3;
[0014] FIG. 5 is a side view of the fastener of FIG. 3 taken in the
direction of arrow 5 of FIG. 3;
[0015] FIGS. 6-19 are illustrations of the steps of the method of
installing a deck system in accordance with the invention.
DETAILED DESCRIPTION
[0016] The system according to a preferred embodiment of the
present invention comprises a composite deck surface having a
structural panel, fastener elements to secure the structural panel
to a deck base, and a surfacing material bonded to the structural
panel.
[0017] Referring to FIG. 1, an exploded perspective view of a
portion of the system 10, a structural panel 12, suitably
comprising a fiber reinforced polymer panel having a grid pattern
of openings 14 in the illustrated embodiment, is adapted to be
received on top of a deck base structure, which may suitably
comprise wood deck framing timbers 16. A fastener element 18,
described in further detail in connection with FIGS. 2-5 herein, is
adapted to be received in an opening 14 so as to engage with the
structural panel 12, seating such that the top surface of the
fastener is below the top surface of the panel 12. The fastener
includes a central hole 20 adapted to receive a fastener
therethrough, to allow securing the panel to the deck framing
timber 16.
[0018] A surfacing material 22, which may comprise a cut stone
having an aesthetically pleasing appearance, color and/or pattern,
is suitably bonded to the structural panel, using a bonding
material 24, for example. The surfacing material may also comprise
tile, dry laid brick, concrete or stone pavers, for example.
[0019] The structural panel is suitably provided in sheets having
dimensions of 4 foot by 8 foot, with a 1.5 inch square grid size,
in the illustrated embodiment. The panel is suitably approximately
1 inch thick. The individual grid openings narrow somewhat from the
top of the panel to the bottom, such that they are wider at the top
face than at the bottom. In the particular embodiment, the opening
is 1- 5/16.sup.th inch at the top measured from interior edge to
the opposite edge of an individual grid opening, but is
11-1/4.sup.th inch at the bottom face of the panel.
[0020] A suitable panel that is employed with the system and method
may be a fiber reinforced general purpose polyester molded resin
panel, although other materials may be used. The panel size is
preferably 4 foot by 8 foot in the preferred embodiment, based on
construction standards and practices, but may be otherwise re-sized
to the desired dimensions, within a 1/16.sup.th inch tolerance, so
as to provide a system that functions with 16 inch framing
dimensions typically used in deck applications. The panel can be
provided in other sizes than the illustrated example, chosen to
have sufficient support while spanning the supporting elements
supporting the panel. Preferably the panel is a pre-configured
dimensional size suitable for compliance with customary building
practices.
[0021] Referring now to FIGS. 2-5, which are views illustrating the
fastener 18 and explaining how it is manufactured, the fastener in
a preferred embodiment is made of a stainless steel material,
stamped to the shape shown in FIG. 2. The fastener is provided with
a row series of twelve teeth 26 on each of 2 sides thereof in a
central region, as well as a corner tooth 28 at each of the four
peripheral corners of the fastener. The corner teeth 28 are on
extended arm portions 34 of the fastener having a slight taper
inwardly on the outer faces thereof, and an arcuate shape on the
inward sides thereof. Teeth 26 and 28 are suitably 3/64.sup.th inch
in height. A central hole 30 is provided in the fastener, as are
two side tabs 32 on opposing sides, next to the sides carrying the
rows of teeth. A slight notch is defined between the tabs 32 and
the arm portions 34.
[0022] After the fastener is formed as in FIG. 2, it is then bent
along lines 36, approximately 90 degrees downwardly, to provide the
configuration visible in FIG. 1 and 5, where the arm portions 34
and teeth 28 form "legs". The central portion of the fastener about
hold 30 is countersunk to provide a 17/32 inch inner diameter flat
bottom countersink, for receiving a fastener head discussed
below.
[0023] In employing the system to provide a deck or patio surface,
the installation steps illustrated in FIG. 6-19 are employed. The
example shown in FIGS. 6-19 is in a deck installation, where a wood
frame deck is present and the system is installed thereon.
[0024] Referring to FIG. 6, first, a waterproof membrane 38, such
as a 40 mil bituminous based material, is placed over the wood
framing to protect the framing from water damage over time. Next,
in FIG. 7, plural structural panels are cut and positions as
necessary to fit over the area of the deck framing that the system
is to be installed upon. Next, (FIG. 8) fasteners 18 are placed
into openings 14 in the structural panel in locations where the
panel is to be secured to the frame 16. The fasteners are tapped
with a hammer so as to have the top surface of the fasteners be
flush with the top surface of the structural panel. Next, as shown
in FIG. 9, a punch (e.g., a 1/2 inch punch) is used with a hammer
to set the fastener in the structural panel. Use of the punch
results in the teeth of the fastener "biting" into the inner walls
of the opening in the structural panel, as well as setting the
fastener to be below the top surface of the structural panel.
[0025] Referring now to FIG. 10, a bead of adhesive material (for
example, fiberglass adhesive) is applied between the joints of the
panel sections. Stainless steel screws are then screwed through the
openings 30 in each fastener, to secure the structural panels to
the deck frame 16, as shown in FIG. 11 and 12, FIG. 12 being a
split view showing both a close up view of a single secured
fastener/screw and a father away view illustrating a wider area,
with 5 fasteners visible.
[0026] An edge trim 40 may now be applied to the peripheral edges
of the assembled structural panel group, by cutting the trim to
length and applying adhesive thereto (to the inside corners of the
edge trim) and then mounting the edge trim to the edges of the
panels (FIGS. 13-15). The edge trim can be, for example, metal edge
trim and may be provided in a variety of colors and finishes, as
desired for the aesthetic taste of the user.
[0027] The surface material 22 is now prepared and applied to the
structural panel, illustrated in FIGS. 16-18. In the illustrated
embodiment, surfacing material 22 comprises quarried stone tiles
having dimensions of 15-3/4 inch by 15-3/4 inch, and approximately
11/32.sup.nd inch thickness. The surface material tiles are first
dry set and cut to fit around any obstacles 42 (a vertical post in
FIG. 16). Next, an adhesive is applied to the back of the stones
and spread with a notched trowel in the particular embodiment
shown. The adhesive suitably comprises Hold-Tite brand adhesive,
suitably an elastomeric polymer. The surface material is now placed
adhesive side down onto the structural panel surface, positioned
suitably with 1/8.sup.th inch spacing between the tiles. The joints
between tiles are not grouted, but are left open, allowing drainage
and room for expansion and providing an appearance that is visually
appealing. FIG. 18 illustrates the steps of placing the tiles in
left, middle and right portions. FIG. 19 illustrates a finished
deck surface employing stone tiles as the surfacing material, with
edge trim on the peripheral edges of the structural panel.
[0028] In an alternative embodiment, the bonding material 24 is
provided in the form of a sheet membrane 24', such as an EPDM
rubber or similar material, which is flexible and soft. The sheet
is suitably 1/16.sup.th inch thick, of dimensions corresponding to
those of the surfacing material 22, and is coated on both sides
with a pressure sensitive contact adhesive. The sheet membrane 24'
is placed onto the surfacing material 22 and then the surfacing
material is placed onto the structural panel 12. This alternative
manner of adhering the material to the panel results in a flexible
bond.
[0029] Accordingly, as system and method are provided whereby a
deck surface of quarried stone is feasible. The use of the fiber
reinforced polymer structural panels, the fasteners and the
adhering of the stone tiles results in a lightweight high strength
system weighing only 8 to 10 pounds per square foot in the
preferred embodiment. The bonding of the surface material to the
structural panel provides further strength to the overall system.
As noted above, other surface materials may be employed, including
but not limited to tile, brick, concrete and stone pavers.
[0030] Under an ASTM #E72-98 test, an exemplary system withstood
6282 lbs. of force with no failure, a maximum 1.47'' deflection and
a maximum 0.35'' set deflection.
[0031] The preferred material for the surfacing material 22 is
natural quarried stone, which includes slates, quartz and
sandstone. All stones are suitably from deep cuts producing the
highest quality and highest density stone for exterior
applications.
[0032] In preferred embodiments, all stones have an ASTM #C121
Water Absorption of 0.10%-0.37%. and an ASTM #C1026 Freeze Thaw
unaffected rating or a natural resistance to damage under these
conditions. Generally all stones have an ASTM #1028 Coefficient of
Friction equal to or greater than most wood or composite products,
so as to not be overly slippery as a walking surface. In most cases
sealing of the surface is not required due to the high density of
this material. However, sealing can enhance the natural beauty if
applied, but it is not required for long term durability.
[0033] Although the illustrated embodiment shows an outdoor
flooring system use for a deck surface mounted to a wood frame,
other uses are also possible. For example, the system and method
can be employed as ground level patios, either as new construction
or to cover a cracked or otherwise undesirable patio, providing
positive drainage. Application to steps is also another use.
Further, the system and method can be employed over waterproofed
living spaces, for example, by placing the structural panels over
the top of the waterproof deck on sleepers (horizontal structural
member on or near the ground that support weight) as a level,
floating deck, without penetrating the waterproof membrane.
[0034] While a preferred embodiment of the present invention has
been shown and described, it will be apparent to those skilled in
the art that many changes and modifications may be made without
departing from the invention in its broader aspects. The appended
claims are therefore intended to cover all such changes and
modifications as fall within the true spirit and scope of the
invention.
* * * * *