U.S. patent application number 17/242255 was filed with the patent office on 2021-08-12 for tile and support structure.
The applicant listed for this patent is MBRICO, LLC. Invention is credited to Jason McManus, Mark A. McManus, Nicholas McManus.
Application Number | 20210246658 17/242255 |
Document ID | / |
Family ID | 1000005542765 |
Filed Date | 2021-08-12 |
United States Patent
Application |
20210246658 |
Kind Code |
A1 |
McManus; Mark A. ; et
al. |
August 12, 2021 |
Tile and Support Structure
Abstract
In one aspect of a reinforced tile, the reinforced tile may be
configured for use with a support structure that may be engaged
with a top portion of a pedestal. The reinforced tile may be
configured with a substrate adhered to a back side of a tile, and
the substrate may be comprised of a fiberglass material A groove
may he formed along at least one edge of the reinforced tile, and
the groove may be positioned at the interface of the tile and
substrate. The support structure may be formed with a generally
vertical spine having at least one rail extending outward from a
distal end thereof. The spine and rail(s) may he configured to
secure one or more reinforced tiles, wherein one or more rails may
be positioned within a groove formed in the reinforced tile.
Inventors: |
McManus; Mark A.;
(Bettendorf, IA) ; McManus; Jason; (Bettendorf,
IA) ; McManus; Nicholas; (Le Claire, IA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MBRICO, LLC |
Bettendorf |
IA |
US |
|
|
Family ID: |
1000005542765 |
Appl. No.: |
17/242255 |
Filed: |
April 27, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16558794 |
Sep 3, 2019 |
10988931 |
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17242255 |
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15881490 |
Jan 26, 2018 |
10934714 |
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16558794 |
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15332700 |
Oct 24, 2016 |
10041254 |
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15881490 |
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14841211 |
Aug 31, 2015 |
9702145 |
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15332700 |
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14524431 |
Oct 27, 2014 |
9151063 |
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14841211 |
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62726236 |
Sep 1, 2018 |
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62394705 |
Sep 14, 2016 |
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62331004 |
May 3, 2016 |
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62245130 |
Oct 22, 2015 |
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61895930 |
Oct 25, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04F 15/02044 20130101;
E04F 2015/02061 20130101; E04F 15/08 20130101; E04D 2001/3447
20130101; E04F 15/02005 20130101; E04B 5/12 20130101; E04D 1/34
20130101; E04F 15/02183 20130101; E04B 5/023 20130101; E04D
2001/3432 20130101; E04F 15/082 20130101; E04F 2015/02094 20130101;
E04B 5/10 20130101; E04F 2015/0205 20130101; E04D 12/004
20130101 |
International
Class: |
E04D 1/34 20060101
E04D001/34; E04F 15/08 20060101 E04F015/08; E04F 15/02 20060101
E04F015/02; E04B 5/02 20060101 E04B005/02 |
Claims
1. A reinforced tile comprising: a. a rectangular tile having a
length, a width, and a thickness, said rectangular tile comprising:
i. a first rectangular face, wherein said first rectangular face is
configured to be generally facing upward during use; ii. a second
rectangular face, wherein said second rectangular face is opposite
said first rectangular face, wherein said first and second
rectangular faces are separated by said thickness of said
rectangular tile, and wherein a surface area of said first and
second rectangular faces is defined by said length and said width
of said rectangular tile; iii. a first, second, third, and fourth
edge defining a periphery of said rectangular tile, wherein said
first, second, third, and fourth edges define said thickness of
said tile; iv. a groove formed in one of said first, second, third,
or fourth edges; b. a substrate engaged with said second
rectangular face, wherein said substrate is comprised of
fiberglass, and wherein said groove is positioned adjacent said
substrate.
2. The tile according to claim 1 wherein said substrate is further
defined as being engaged with said tile via a two-part, epoxy.
3. The tile according to claim 2 wherein said tile is further
defined as being constructed of porcelain.
4. The tile according to claim 3 wherein said substrate is further
defined as being comprised of a pultruded fiberglass material.
5. The reinforced tile according to claim 4 wherein said groove is
further defined as being formed on said first edge, and wherein
said reinforced tile further comprises a protrusion formed on said
second edge.
6. The reinforced tile according to claim 5 wherein said groove is
further defined as a height that is parallel to said thickness of
said tile and a depth that is parallel to said width of said
tile.
7. The reinforced tile according to claim 6 wherein said depth of
said groove is greater than said height of said groove.
8. The reinforced tile according to claim 7 wherein a thickness of
said substrate is greater than said height of said groove.
9. A method of constructing a reinforced tile, said method
comprising the steps of: a. selecting a generally rectangular tile
having a length, a width, and a thickness, said rectangular tile
comprising: i. a first rectangular face, wherein said first
rectangular face is configured to be generally facing upward during
use; ii. a second rectangular face, wherein said second rectangular
face is opposite said first rectangular face, wherein said first
and second rectangular faces are separated by said thickness of
said rectangular tile, and wherein a. surface area of said first
and second rectangular faces is defined by said length and said
width of said rectangular tile; and, iii. a first, second, third,
and fourth edge defining a periphery of said rectangular tile,
wherein said first, second, third, and fourth edges define said
thickness of said tile; b. applying a two-part epoxy to said second
rectangular face; c. selecting a generally rectangular substrate;
d. aligning said generally rectangular substrate with said second
rectangular face of said tile; e. pressing said substrate against
said second rectangular face; and, f. forming a groove in said
first edge of said reinforced tile.
10. The method according to claim 9 wherein said groove is further
defined as being formed in said substrate.
11. A method of securing a plurality of reinforced tiles in three
dimensions, said method comprising: a. positioning a first support
structure in a first direction, wherein said first support
structure is configured as an elongate rail, and wherein said first
support structure comprises: i. a base with a generally planar
upward-facing surface; ii. a plurality of anchors positioned along
a length of said base; b. positioning a second support structure in
said first direction, wherein said second support structure is
configured as an elongate rail, wherein said first and second
support structures are parallel with respect to one another and
separated from one another by a first distance, and wherein said
second support structure comprises: i. a base with a generally
planar upward-facing surface; ii. a plurality of anchors positioned
along a length of said base; c. positioning a first reinforced tile
of said plurality on said generally planar upward-facing surface of
said first support structure and said generally planar
upward-facing surface of said second support structure, wherein
said first reinforced tile has a major height, a major width, and a
thickness, and wherein first reinforced tile comprises: i. a first
face, wherein said first face is configured to be generally facing
upward during use; ii. a second face, wherein said second face is
opposite said first face, and wherein said first and second faces
are separated by said thickness of said reinforced tile; iii. a
substrate engaged with said second face; iv. an edge defining a
portion of a periphery of said reinforced tile; v. a. groove formed
in said edge; d. positioning a first portion of a retainer in said
groove; e. aligning an aperture formed in a geometric center of
said retainer with a first anchor of said plurality; f. inserting a
first portion of a fastener through said aperture in said retainer;
g. engaging said first portion of said fastener with said first
anchor thereby securing a relative position of said first
reinforced tile with respect to said first and second support
structures simultaneously in a vertical dimension and a first
horizontal dimension perpendicular to said length of said bases of
said first and second support structures; h. positioning a second
reinforced tile of said plurality on said generally planar
upward-facing surface of said first support structure and said
generally planar upward-facing surface of said second support
structure, wherein said second reinforced tile has a major height,
a major width, and a thickness, and wherein second reinforced tile
comprises: i. a first face, wherein said first face is configured
to be generally facing upward during use; ii. a second face,
wherein said second face is opposite said first face, and wherein
said first and second faces are separated by said thickness of said
second reinforced tile; iii. a substrate engaged with said second
face; iv. an edge defining a portion of a periphery of said second
reinforced tile; v. a second edge defining a second portion of said
periphery of said second reinforced tile; vi. a groove formed in
said edge; i. ensuring that said second edge of said second
reinforced tile is positioned adjacent a structure configured to
secure a relative position of said second reinforced tile with
respect to said first and second support structures simultaneously
in said vertical dimension and said first horizontal dimension, and
simultaneously securing said relative position of said first
reinforced tile with respect to said first and second support
structures in a second horizontal dimension parallel to said length
of said bases of said first and second support structures; j.
positioning a first portion of a second retainer in said groove of
said second reinforced tile; k. aligning an aperture formed in a
geometric center of said second retainer with a second anchor of
said plurality; l. inserting a first portion of a second fastener
through said aperture in said second retainer; and, m. engaging
said first portion of said second fastener with said second anchor
thereby securing a relative position of said second reinforced tile
with respect to said first and second support structures
simultaneously in said vertical dimension and said first horizontal
dimension. perpendicular to said length of said bases of said first
and second support structures.
12. The method according to claim 11 further comprising the steps
of: a. positioning a third support structure in said first
direction, wherein said third support structure is configured as an
elongate rail, wherein said second and third support structures are
parallel with respect to one another and separated from one another
by a second distance, and wherein said third support structure
comprises: i. a base with a generally planar upward-facing surface;
and ii. a plurality of anchors positioned along a length of said
base.
13. The method according to claim 12 wherein said first support
structure further comprises a plurality of apertures formed
therein.
14. The method according to claim 13 wherein said groove in said
first reinforced tile is further defined as being formed on said
first edge, and wherein said reinforced tile further comprises a
protrusion formed on said second edge.
15. The method according to claim 14 wherein said groove in said
first reinforced tile is further defined as having a height that is
parallel to said thickness of said reinforced tile and a depth that
is parallel to said width of said reinforced tile.
16. The method according to claim 15 wherein said depth of said
groove is greater than said height of said groove.
17. The method according to claim 16 wherein a thickness of said
substrate is greater than said height of said groove.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present non-provisional patent application is a
continuation of and claims priority from U.S. patent application
Ser. No. 16/558,794 filed on Sep. 3, 2019, which application
claimed priority from provisional Pat. App. No. 62/726,236 filed on
Sep. 1, 2018, and which patent application was a
continuation-in-part of and claimed priority from U.S. patent
application Ser. No. 15/881,490 filed on Jan. 26, 2018, which
application was a continuation and claimed priority from U.S.
patent application Ser. No. 15/332,700 filed on Oct. 24, 2016,
which application claimed priority from provisional U.S. Pat. App.
Nos. 62/245,130 filed on Oct. 22, 2015; 62/331,004 filed on May 3,
2016; and, 62/394,705 filed on Sep. 14, 2016, and which application
also was a continuation-in-part of and claimed priority from U.S.
patent application Ser. No. 14/841,211, now U.S. Pat. No.
9,702,145, filed on Aug. 31, 2015, which application was a
continuation of and claimed priority from U.S. patent application
No. 14/524,431, now U.S. Pat. No. 9,151,063, filed on Oct. 27,
2014, which application claimed priority from provisional U.S. Pat.
App. No. 61/895,930 filed on Oct. 25, 2013, all of which
applications are incorporated by reference herein in their
entireties.
FIELD OF THE INVENTION
[0002] The present disclosure relates to a tile and tile support
structure allowing use of placement of porcelain tiles for tiled
surfaces, such as outdoor deck systems and/or roof systems.
AUTHORIZATION PURSUANT TO 37 C.F.R. .sctn. 1.171 (c)
[0003] A portion of the disclosure of this patent document may
contain material that is subject to copyright and trademark
protection. The copyright owner has no objection to the facsimile
reproduction by anyone of the patent document or the patent
disclosure, as it appears in the Patent and Trademark Office patent
file or records, but otherwise reserves all copyrights
whatsoever.
BRIEF DESCRIPTION OF FIGURES
[0004] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments and
together with the description, serve to explain the principles of
the methods and systems.
[0005] FIG. 1 is a perspective view of one arrangement of a
plurality of illustrative joists configured in a manner that is
typical for a building structure.
[0006] FIG. 2 is a perspective view of the joists from FIG. 1
having a plurality of illustrative support structures engaged with
the joists.
[0007] FIG. 3 is a perspective view of the joists and support
structures from FIG. 2 wherein a plurality of illustrative tiles
are engaged with the support structures.
[0008] FIG. 4 is a top view of the support structures and tiles
shown in FIG. 3.
[0009] FIG. 5 is a detailed perspective view of a portion of the
joists, support structures, and tiles shown in FIGS. 3 and 4.
[0010] FIG. 6 is another detailed perspective view of a portion of
the joists, support structures, and tiles shown in FIGS. 3 and
4.
[0011] FIG. 7 is a perspective view of the illustrative support
structure shown in FIGS. 2-6.
[0012] FIG. 8 is a cross-sectional view of the illustrative support
structure shown in FIGS. 2-7.
[0013] FIG. 9 is a cross-sectional view of an illustrative edge
support structure.
[0014] FIG. 10 is a perspective view of an illustrative tile that
may be used with various aspects of a support structure.
[0015] FIG. 11A is a cross-sectional view of another illustrative
support structure showing dimensions of various elements
thereof.
[0016] FIG. 11B is a cross-sectional view of another illustrative
support structure showing dimensions of various elements
thereof.
[0017] FIG. 11C is a cross-sectional view of another illustrative
support structure showing dimensions of various elements
thereof.
[0018] FIG. 11D is a cross-sectional view of another illustrative
support structure showing dimensions of various elements
thereof.
[0019] FIG. 11E is a cross-sectional view of another illustrative
support structure showing dimensions of various elements
thereof.
[0020] FIG. 12A is a detailed perspective view showing various
aspects of a tile engaged with an illustrative support
structure.
[0021] FIG. 12B is a detailed perspective view showing various
aspects of two illustrative tiles engaged with an illustrative
support structure.
[0022] FIG. 12C is a perspective view of a portion of a deck
constructed according to various aspects of the present
disclosure.
[0023] FIG. 13 is an end view showing various aspects of a roof
support structure.
[0024] FIG. 14 is an end view showing other aspects of a roof
support structure.
[0025] FIG. 15A is an end view showing other aspects of a roof
support structure.
[0026] FIG. 15B is an end view showing other aspects of a roof
support structure.
[0027] FIG. 16A is a top view of a tile and support structure that
may be configured for use with pedestals.
[0028] FIG. 16B is an end view of the tile and support structure
shown in FIG. 16A.
[0029] FIG. 17A is a cross-sectional view showing other aspects of
a support structure.
[0030] FIG. 17B is a cross-sectional view showing further aspects
of a support structure.
[0031] FIG. 17C is a cross-sectional view showing still further
aspects of a support structure.
[0032] FIG. 17D is a cross sectional view of the support structure
shown in FIG. 17C with the fastener and retaining element
installed.
[0033] FIG. 18 is a cross-sectional view of a retaining element
that may be used on a border.
[0034] FIG. 19A provides an elevated perspective view showing
aspects of a support system that may be engaged with a
pedestal.
[0035] FIG. 19B provides a side view of the support system and
pedestal shown in FIG. 19A.
[0036] FIG. 20A provides an elevated perspective view showing
further aspects of a support system that may be engaged with a
pedestal.
[0037] FIG. 20B provides a side view of the support system and
pedestal shown in FIG. 20A.
[0038] FIG. 21 provides a side view of another aspect of a support
system that may be engaged with a pedestal.
[0039] FIG. 22A provides a top view showing additional aspects of a
support system that may be engaged with a pedestal.
[0040] FIG. 22B-23B provide various top views of a support system
that may be engaged with a pedestal.
[0041] FIG. 24A provides a side view of an illustrative embodiment
of a reinforced tile.
[0042] FIG. 24B provides a side view of a second illustrative
embodiment of a reinforced tile.
[0043] FIG. 24C provides a side view of a third illustrative
embodiment of a reinforced tile.
[0044] FIG. 25A provides a perspective view of an illustrative
embodiment of a reinforced tile haying a groove formed therein.
[0045] FIG. 25B provides a side view of an illustrative embodiment
of a reinforced tile having a groove formed therein.
[0046] FIG. 26A provides an end view of another illustrative
embodiment of a reinforced tile having a groove formed therein.
[0047] FIG. 26B provides another end view of the illustrative
embodiment of a reinforced tile shown in FIG. 26A.
[0048] FIG. 27A provides a perspective view of another illustrative
embodiment of a reinforced tile engaged with a support
structure.
[0049] FIG. 27B provides a side view of the illustrative embodiment
of a reinforced tile engaged. with a support structure from FIG.
27A.
DETAILED DESCRIPTION--LISTING OF THE ELEMENTS
TABLE-US-00001 [0050] Element Description Element Number Tile &
support structure 10 Deck 12 Joist 14 Fastener 16 Substrate 18 Lath
19 Tile 20 Face 22 Edge 24 Groove 24a Protrusion 24b Clearance 25
Support structure 30 Edge support structure 30a Base 31 Flange 32
Trough 32a Aperture 32b Lip 33 Spine 34 Tip 34a Rail 36 Anchor 38
Roof support structure 30' Roof edge support structure 30a' Base
31' Flange 32' Trough 32a' Aperture 32b' Lip 33' Spine 34' Tip 34a'
Rail 36' Channel portion 37' Side member 37a' Notch 37b' Bottom
member 37c' Inner member 40 Inner member bottom 42 Inner member
side 44 Pedestal 50 Pedestal base 52 Adjustment portion 53 Pedestal
upper surface 54 Retaining element 60 Neck 62 Retaining element 60'
Neck 62' Securement clip 70 Vertical member 72 Ramp 72a Catch 72b
Base member 74 Reinforced tile 120 Substrate 120a
DETAILED DESCRIPTION OF INVENTION
[0051] Before the present methods and systems are disclosed and
described, it is to be understood that the methods and systems are
not limited to specific methods, specific components, or to
particular implementations. It is also to be understood that the
terminology used herein is for the purpose of describing particular
embodiments only and is not intended to be limiting.
[0052] As used in the specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents unless
the context clearly dictates otherwise. Ranges may be expressed
herein as from "about" one particular value, and/or to "about"
another particular value. When such a range is expressed, another
embodiment includes from the one particular value and/or to the
other particular value. Similarly, when values are expressed as
approximations, by use of the antecedent "about," it will be
understood that the particular value forms another embodiment. It
will be further understood that the endpoints of each of the ranges
are significant both in relation to the other endpoint, and
independently of the other endpoint.
[0053] "Optional" or "optionally" means that the subsequently
described event or circumstance may or may not occur, and that the
description includes instances where said event or circumstance
occurs and instances where it does not.
[0054] Throughout the description and claims of this specification,
the word "comprise" and variations of the word, such as
"comprising" and "comprises," means "including but not limited to,"
and is not intended to exclude, for example, other components,
integers or steps. "Exemplary" means "an example of" and is not
intended to convey an indication of a preferred or ideal
embodiment. "Such as" is not used in a restrictive sense, but for
explanatory purposes.
[0055] Disclosed herein are various components that may be used to
perform the disclosed methods and provide the disclosed systems.
These in addition to other components that may be compatible with
the disclosed methods and systems, and it is understood that when
combinations, subsets, interactions, groups, etc. of these
components are disclosed, that while specific reference of each
various individual and collective combinations and permutation of
these may not be explicitly disclosed, each is specifically
contemplated and described herein, for all methods and systems of
the present disclosure. This applies to all aspects of this
disclosure including, but not limited to, steps in disclosed
methods. Thus, if there are a variety of additional steps that may
be performed, it is understood that each of these additional steps
may be performed with any specific aspects or combination of
aspects of the disclosed methods.
[0056] The present methods and systems may be understood more
readily by reference to the following detailed description of
systems and methods (including the various aspects thereof) and the
examples included therein and to the Figures and their following
description. Further, although some figures included herewith show
various dimensions of some features of certain illustrative aspects
of certain components of the present disclosure, such dimensions
are for illustrative purposes only and in no way limit the scope of
the present disclosure unless so indicated in the following
claims.
[0057] The following detailed description is of the best currently
contemplated modes of carrying out the present methods and systems.
The description is not to be taken in a limiting sense, but is made
merely for the purpose of illustrating the general principles of
the various aspects of the present disclosure, since the scope of
the invention is best defined by the appending claims. Various
inventive features are described below herein that can each be used
independently of one another or in combination with other features
without limitation unless so indicated in the following claims.
[0058] A group of joists 14 in a typical arrangement is shown in
FIG. 1, wherein the joists 14 are oriented parallel with respect to
one another about their lengths. It is contemplated that in certain
illustrative aspects of a tile and support structure 10 as
disclosed herein, the tile and support structure 10 may be adapted
for use with such joists 14 and/or arrangements thereof. However,
the tile and support structure 10 may be used with other
structures, structural components, and/or surfaces as described in
detail below, and the use of joists 14 is therefore in no way
limiting to the scope of the present disclosure unless so indicated
in the following claims.
[0059] As shown in FIG. 2, a plurality of support structures 30 may
be engaged with the joists 14 such that the support structures 30
may be oriented parallel with respect to one another along their
lengths. It is contemplated that the support structures 30 may be
engaged with the top edge of the joists 14 via one or more
fasteners 16 in a manner similar to that in which decking material
may be engaged with joists 14. In one aspect, the fasteners 16 may
be configured as wood screws. However, the specific method and/or
structure used to engage the support structures 30 with the joists
14 (or other structure, structural component, and/or surface) in no
way limits the scope of the present disclosure unless so indicated
in the following claims. Additionally, the support structures 30
may be oriented such that they are not perpendicular with respect
to the joists 14 (or other structure, structural component, and/or
surface), but such that the support structures 30 are still
oriented parallel with respect to one another without limitation
unless so indicated in the following claims.
[0060] The support structures 30 may be configured such that they
are oriented perpendicular with respect to the joists 14. In such a
configuration, the joists 14 and support structures 30 may form a
grid. In certain aspects it may be advantageous to position a cross
lathe (not shown) under each support structure 30. In one aspect,
the cross lathe may be configured as a wooden one-by-three inch
board, a wooden one-by-four inch board, or any other suitable
structure without limitation, including but not limited to plastic
and/or polymer strips, unless so indicated in the following claims.
The cross lathe and support structure 30 may be engaged with one
another and the joists 14 and the relative positions thereof
secured via one or more fasteners 16. It is contemplated that such
a configuration may be especially useful if there is a reasonable
likelihood that the position of the joists 14 and/or other
underlying structure might shift over time. Accordingly, the scope
of the present disclosure is in no way limited by whether a cross
lathe is used unless so indicated in the following claims.
Furthermore, the specific method and/or structure used to engage
the cross lathes with the joists 14 and/or support structures 30 in
no way limits the scope of the present disclosure unless so
indicated in the following claims.
[0061] A perspective view of the joist 14 and support structure 30
grid after a plurality of tiles 20 have been engaged with the
support structures 30 is shown in FIG. 3. A top view is shown in
FIG. 4, and FIGS. 5 and 6 provide two detailed perspective views.
Those of ordinary skill in the art will recognize the arrangement
in FIG. 3 as one arrangement of a deck 12 that may be constructed
according to various aspects of the present disclosure. Although
the tiles 20 pictured in FIG. 3 are configured as rectangles, the
scope of the present disclosure is not so limited unless so
indicated in the following claims. In another aspect not pictured
herein, the shape of the tiles 20 is square. In still another
aspect not pictured herein, the shape of the tiles 20 is a
parallelogram, and in still another aspect the shape of the tiles
20 is a rhombus. As described in detail below, other aspects of the
present disclosure may be configured to accommodate tiles 20 having
one or more non-linear edge. Additionally, in certain aspects of a
deck 12 constructed using the tile and support structure 10
disclosed herein, certain tiles 20 at the edges and/or corners of
the deck 12 may be irregularly shaped, and may have more than four
sides or fewer than four sides without limitation unless so
indicated in the following claims, and which will depend at least
upon the configuration of the deck 12.
[0062] A perspective view showing various illustrative aspects of a
support structure 30 according to the present disclosure is shown
in FIG. 7, and a cross-sectional view thereof is shown in FIG. 8.
The support structure 30 may include a base 31 having a first and
second flange 32 extending outward from a generally vertical
centerline of the support structure 30. Each flange 32 may be
formed with a trough 32a therein, and each trough 32a may be formed
with a plurality of apertures 32b therein, as shown at least in
FIG. 7. The distal edge of each trough 32a may be bound by a lip
33, wherein the top surface of each lip 33 may be coplanar with the
top surface of each flange 32. Such a configuration may spread the
force associated with a tile 20 engaged with a given support
structure 30 over a larger area, as explained in further detail
below.
[0063] In one illustrative asepct, the apertures 32b formed in a
given trough 32a may be spaced from one another by a distance of
four inches such that a support structure 30 may he engaged with
joists 14 spaced twelve or sixteen inches from adjacent joists 14
without need to modify the support structure 30. In such a
configuration, it is contemplated that multiple apertures 32b will
not have a fastener 16 positioned therein, such that those
apertures 32b may serve as an egress point for water and/or other
liquid and/or precipitation in the trough 32a, and the trough 32a
may serve as a fluid conduit (e.g., gutter) for water and/or other
precipitation and/or liquids. However, the spacing of the apertures
32b in no way limits the scope of the present disclosure unless so
indicated in the following claims. Additionally, the apertures 32b
may be tapered such that the head of a fastener 14 configured as a
screw may seat within the aperture 32b, and such that in certain
aspects the head of a fastener 14 may be flush with the bottom of
the trough 32a, and/or such that the head of a fastener 14 may be
positioned below the upper surface of the flange 32. However, other
aspects of the apertures 32b may be differently configured without
limitation unless so indicated in the following claims.
[0064] A spine 34 may extend upward from the base 31 along the
vertical centerline of the support structure 30. At the top distal
end of the spine 34, two corresponding rails 36 may extend outward
from the spine 34 in a generally horizontal dimension. A tip 34a
that may be collinear with the spine 34 may extend downward from
the spine 34 such that the distal end of the tip 34a. is coplanar
with the bottom surface of the base 31. Such a configuration may
allow the tip 34a to abut a joist 14 and/or cross lathe during use.
In certain aspects, it may be advantageous to construct the support
structure 30 of a metal or metallic alloy. However, the support
structure 30 may be constructed of any suitable material, including
but not limited to plastic, polymers, natural materials, and/or
combinations thereof without limitation unless so indicated in the
following claims.
[0065] A cross-sectional view showing various illustrative aspects
of an edge support structure 30a, which may be correlative to
various illustrative aspects of a support structure 30 shown in
FIGS. 7 and 8, is shown in FIG. 9. The edge support structure 30a
may include a base 31 having a first flange 32 extending outward
therefrom. The flange 32 may be formed with a trough 32a therein,
and the trough 32a may be formed with a plurality of apertures 32b
therein. The distal edge of the trough 32a may be bound by a lip
33, wherein the top surface of each lip 33 may be coplanar with the
top surface of the flange 32. Such a configuration may spread the
force associated with a tile 20 engaged with a given edge support
structure 30a over a larger area, as explained in further detail
below.
[0066] In an illustrative aspect, the apertures 32h formed in the
trough 32a of the edge support structure 30a may be spaced from one
another by a distance of four inches, such that an edge support
structure 30a may be engaged with joists 14 spaced twelve or
sixteen inches from adjacent joists 14 without need to modify the
edge support structure 30a. However, the spacing of the apertures
32b in no way limits the scope of the present disclosure unless so
indicated in the following claims. Additionally, the apertures 32b
may be tapered such that the head of a fastener 14 configured as a
screw may seat within the aperture 32b, and such that in certain
aspects the head of a fastener 14 may be flush with the bottom of
the trough 32a. However, other aspects of the apertures 32b may be
differently configured without limitation unless so indicated in
the following claims.
[0067] A spine 34 may extend upward from the base 31 in a generally
vertical dimension. At the top distal end of the spine 34, a rail
36 may extend outward from the spine 34 in a generally horizontal
dimension, wherein the rail 36 may be generally parallel with
respect to the flange 32 and generally perpendicular with respect
to the spine 34. A tip 34a that may be collinear with the spine 34
may extend downward from the spine 34 such that the distal end of
the tip 34a is coplanar with the bottom surface of the base 31.
Such a configuration may allow the tip 34a to abut a joist 14
and/or cross lathe during use.
[0068] The various relative dimensions of the components of the
support structure 30 may be infinitely varied depending on the
specific application of the support structure 30. Several
illustrative aspects of different support structures 30 according
to the present disclosure and dimensions of the components of the
support structure 30 are shown in FIGS. 11A-11E. However, these
aspects and dimensions are not meant to be limiting in any sense,
but rather are provided to show how the various dimensions of the
support structure 30 may he manipulated without departing from the
spirit and scope of the present disclosure unless so indicated in
the following claims.
[0069] Various illustrative aspects of a tile 20 that may be
engaged with the illustrative embodiment of a support structure 30
are shown in FIG. 10. The tile 20 may be generally rectangular in
shape (as shown in FIG. 3), such that two rectangular-shaped faces
22 are spaced from one another by the height of an edge 24 of the
tile 20. In one aspect, the height of an edge 24 may be 20
millimeters, and in another asepct the height thereof may be 30
millimeters. However, as previously mentioned, the scope of the
present disclosure is not limited by the specific shape,
dimensions, and/or configuration of the tile 20 unless so indicated
in the following claims. The bottom face 22 may be engaged with a
substrate 18, which may be configured as a synthetic (e.g.,
fiberglass, plastic, etc.) sheet haying a periphery equal to or
approximately equal to that of the tile 20. In one aspect, the
thickness of a substrate may be 3/4 of an inch, but the specific
dimensions of the substrate 18, if used for that aspect of a tile
20, is in no way limiting to the scope of the present disclosure
unless so indicated in the following claims. If a substrate 18 is
used, it may be engaged with the tile 20 using any suitable
structure and/or method suitable for the particular application of
the tile 20, including but not limited to chemical adhesives,
mechanical fasteners, and/or combinations thereof The scope of the
present disclosure is in no way limited by whether a substrate 18
is engaged with a tile 20 unless so indicated in the following
claims.
[0070] Opposite edges 24 of a tile 20 may be formed with a groove
24a therein, as shown in FIGS. 10, 12A, and 12B. The groove 24a may
be formed in the edge 24 of the tile 20, in a portion of the edge
24 of the tile 20, in a portion of a surface of a substrate 18 (if
present), and/or a combination of a portion of the tile 20 and a
portion of the substrate 18. The groove 24a may be configured such
that it cooperates with the rail 36 at the top distal end of the
spine 34, and such that the bottom face 22 of the tile 20 (or
bottom surface of the substrate 18, if present for that embodiment
of a tile 20) rests upon the top surface of the flange 32 and lip
33, as clearly shown at least in FIGS. 12A and 12B. Accordingly,
one tile 20 may be engaged on opposing edges 24 of the tile 20 with
adjacent support structures 30. In this manner, the tile 20 may
slide with respect to the support structures 30 along the lengths
of the support structures 30, Such a configuration allows adjacent
tiles 20 between corresponding support structures 30 to be slid
into place from an open end of the support structures 30 until the
final tile 20 is positioned. Simultaneously, this configuration may
secure the relative position of the tile 20 with respect to the
support structures 30 in all other dimensions (e.g., a vertical
dimension and a horizontal dimension perpendicular with respect to
the length of the support structures 30). It is contemplated that
the dimensions of the groove 24a may be selected such that a common
blade and/or tool may be used to form the required groove 24a in a
given edge 24. It is also contemplated that in certain aspects of a
tile and support structure 10, a predetermined shown of space may
exist between the surfaces of a groove 24a and the surfaces of a
rail 36, between the edge 24 and the spine 34, and between the
bottom face 22 and flange 32 such that water and/or other liquids
and/or other precipitation may flow via gravity between the groove
24a and the rail 36, between the edge 24 and spine 34, and/or
between the bottom face 22 and flange 32.
[0071] Referring now specifically to FIG. 12B, the grooves 24a and
the support structure 30 may be configured such that a clearance 25
exists between adjacent tiles 20 on opposing sides of a support
structure 30. In an illustrative aspect, the width of the clearance
25 may be 1/8 of an inch. The various dimensions of the tile (e.g.,
edge 24, groove 24a, etc.) and support structure 30 (e.g., height
and width of spine 34, length of rail 36, etc.) may he varied to
change the width and depth of the clearance 25, and the optimal
width and depth of the clearance 25 may vary from one application
of the tile and support structure 10 to the next. Accordingly, the
scope of the present disclosure is in no way limited by the
specific dimensions and/or configuration of the clearance 25 unless
so indicated in the following claims.
[0072] Still referring to FIGS. 12A and 12B, the tile 20 may be
formed with a protrusion 24b on an edge 24 thereof not configured
with a groove 24a. The protrusions 24b may be configured such that
when protrusions 24a of adjacent tiles 20 abut one another, the
space between the edges 24 thereof is equal or approximately equal
to the width of the clearance 25 between edges 24 of adjacent tiles
20 having grooves 24a formed therein. Various illustrative aspects
of a portion of a deck 12 employing a tile and support structure 10
so configured is shown in FIG. 12C. However, in other aspects not
pictured herein, the space between adjacent tiles 20 along edges 24
thereof having protrusions 24b may be different that the width of
the clearance 25 without limitation unless so indicated in the
following claims. It is contemplated that the clearance 25 and/or
space between the edges 24 of adjacent tiles 20 having protrusions
24b formed therein may facilitate drainage of water and/or other
liquids from the top face 22 of the tile 20 (and/or an area
adjacent thereto) to an area below the tile 20, the path for which
may proceed into the trough 32a and out through one or more
apertures 32b. However, the specific spacing between any edge 24 of
adjacent tiles 20 may vary according to the present disclosure
without limitation unless so indicated in the following claims.
[0073] It is contemplated that for certain applications of the tile
and support structure 10, it may be especially advantageous to
construct the tile 20 from porcelain or stone, the substrate 18 (if
present) from fiberglass, and the support structure 30 from
aluminum. However, the tile and support structure 10 and various
elements thereof may be constructed of any suitable material known
to those skilled in the art without limitation unless so indicated
in the following claims. Accordingly, the present methods and
systems may work with any tile-based product, particularly tile
made of clay. As disclosed herein, a tile 20 suitable for use as a
deck tile may be comprised of fiber glass fiber and clay. For
certain applications it may be desirable to configured the tile 20
such that not less than one-percent is fiberglass fiber by weight.
Another tile 20 that may be suitable for certain applications
according to the present disclosure may be comprissed of fiber
glass fiber and clay, with not less than twenty-five percent
fiberglass fiber by weight. For certain applications, it may be
advantageous for a tile 20 to have a width of approximately twelve
inches, a length of approximately twenty-four inches, and a
thickness of one to one and one half inches, without limitation
unless so indicated in the following claims.
Illustrative Aspects of a Roofing Application
[0074] In another aspect of a tile and support structure 10
disclosed herein, the tile and support structure 10 may be
configured for use in a roofing application. End views showing
various aspects of a tile and support structure 10 configured for
use in a roofing application are shown in FIGS. 13-16. The upper
surface of a roof support structure 30' may be configured in a
manner similar to that as previously described herein for a support
structure 30. As shown in FIG. 13, which provides a cross-sectional
view showing various aspects of a roof support structure 30', a
roof support structure 30' may be comprised of a channel portion
37' to which a support structure 30 may be engaged. It is
contemplated that the roof support structures 30' shown in FIGS.
13-15 may be configured as elongate members, such as rails.
However, the scope of the present disclosure is not so limited
unless so indicated in the following claims.
[0075] The support structure 30 and channel portion 37' may be
separately formed and then later engaged with one another (e.g.,
via welding, mechanical fasteners, chemical adhesives, etc.) or
integrally formed with one another during manufacturing without
limitation unless so indicated in the following claims. Any
suitable structure and/or method may be used to engage the support
structure 30 with the channel portion 37' without limitation unless
so indicated in the following claims. Any of the various aspects,
features, configurations, etc. of a support structure 30 disclosed
herein may be engaged with a channel portion 37' to form a roof
support structure 30' without limitation unless so indicated in the
following claims. Additionally, any of the various aspects,
features, configurations, etc. of an edge support structure 30a
disclosed herein may be engaged with a channel portion 37' and/or
corresponding portion thereof to form an edge roof support
structure 30a' without limitation unless so indicated in the
following claims.
[0076] Referring still to FIG. 13, in an aspect of a roof support
structure 30', the bottom surface of the base 31' may be configured
in a manner that is similar to the support structures 30 previously
disclosed herein, wherein two opposing flanges 32' may extend
outward from a center of the base 31', and such that a tip 34a' may
extend downward from the base 31'. That is, there may be open areas
on either side of the tip 34a' on the bottom side of each flange
32. The tip 34a' may be collinear with the spine 34', and a trough
32a' may be formed in each flange 32'. A plurality of apertures
32b' may be formed each either trough 32a'. Each flange 32' may
terminate at a lip 33', and to top surface of each flange 32' at
the lip 33' and adjacent the spine 34' may be collinear as
previously described for other aspects of a tile and support
structure 10.
[0077] The channel portion 37' may include one or more side members
37a', which may extend downward from the either distal end of the
base 31' (which distal end may be adjacent a lip 33') of the roof
support structure 30'. The side members 37a' may terminate at a
bottom member 37c', which bottom member 37c' may be configured such
that it is generally perpendicular with respect to the side members
37a'. A notch 37b' may be formed in a side member 37a' between the
bottom member 37c' and the base 31'. In an aspect of a roof support
structure 30', the roof support structure 30' may be formed with
two distinct bottom members 37c' at the terminal end of two
distinct side members 37a', as shown at least in FIGS. 13, 14,
& 15A, both of which are perpendicular with respect to the side
members 37a' but parallel with respect to one another. In another
aspect of a roof support structure 30', the roof support structure
30' may be formed with one continuous bottom member 37c' engaged
with each side member 37a', as shown at least in FIG. 15B, which
continuous bottom member 37c' may be perpendicular with respect to
either side member 37b'. Accordingly, the specific configuration of
the bottom member(s) 37c' in no way limits the scope of the present
disclosure unless so indicated in the following claims.
[0078] Referring now to FIG. 14, in an aspect of a roof support
structure 30', the bottom surface of the base 31' may be configured
such that it is planar. That is, the open areas on either side of
the tip 34a' on the bottom side of each flange 32' (such as shown
in FIG. 13) may be solid, which may be especially beneficial in
aspects of a roof support structure 30' that is manufactured as an
integral unit. In such a configuration, the roof support structure
30' may not include a tip 34a'. The channel portion 37' may include
one or more side members 37a' extending downward from the distal
ends of the base 31'(which distal end may be adjacent a lip 33').
The side members 37a' may terminate at a bottom member 37c', which
bottom member 37c' may be configured such that it is generally
perpendicular with respect to the side members 37a'. A notch 37b'
may be formed in a side member 37a' between the bottom member 37c'
and the base 31'. As previously described with respect to FIG. 13,
the roof support structure 30' may be formed with two distinct
bottom members 37c' at the terminal end of two distinct side
members 37a', as shown at least in FIGS. 13, 14, & 15A, both of
which are perpendicular with respect to the side members 37a' but
parallel with respect to one another. In another aspect of a roof
support structure 30', the roof support structure 30' may be formed
with one continuous bottom member 37c' engaged with each side
member 37a', as shown at least in FIG. 15B, which continuous bottom
member 37c' may be perpendicular with respect to either side member
37b'. Accordingly, the specific configuration of the bottom
member(s) 37c' in no way limits the scope of the present disclosure
unless so indicated in the following claims.
[0079] Referring now to FIGS. 13 & 14, a roof support structure
30' may utilize an inner member 40, a portion of which may be
positioned within and engaged with a channel portion 37' of the
roof support structure 30'. The inner member 40 may include an
inner member bottom 42 and one or more inner member sides 44
extending upward from the inner member bottom 42. The inner member
40 may be engaged with the roof support structure 30', which
engagement be via any suitable structures and/or methods without
limitation unless so indicated in the following claims.
[0080] It is contemplated that in roof support structure 30'
configured to use an inner member 40, the inner member 40 may be
engaged with one or more pedestals 50. Additionally, it is
contemplated that for roof support structures 30' configured
without an inner member 40, such as those shown in FIGS. 15A &
15B, may he engaged with one or more pedestals 50. For example,
Eurotec, GmbH from Germany manufactures pedestals that may be
configured with a "click adaptor" on a portion of the top surface
of the pedestal, as shown on page 6 of Appendix A, which
incorporated in and made a part of this disclosure. With a pedestal
so configured, a roof support structure 30' (or correlative support
structure 30) may be engaged with the pedestal 50 and click
adapter, wherein a portion of that engagement may occur at the
notch(s) 37b', and another portion of the engagement may consist of
the bottom member(s) 37c' resting on the top surface of the
pedestal 50. Generally, in one aspect a pedestal 50 may be engaged
with suitable structures, structural components, surfaces and/or
methods for forming an underlying support for a tile and support
structure 10, which suitable structures, structural components,
surfaces, and/or methods for forming an underlying support for a
tile and support structure 10 include but are not limited to steel,
other metals, metallic alloys, synthetic materials, cement,
concrete, wood, ceramics, etc. unless so indicated in the following
claims.
[0081] Referring now to FIGS. 16A & 16B, an aspect of a roof
support structure 30' may include one or more pedestals 50. It is
contemplated that the pedestal base 52 may be engaged with a
structure, such as a concrete surface, a wooden surface, or other
structure, structural component, and/or surface on which a tile and
support structure 10 may be positioned. However, any suitable
structure and/or surface may be used, including but not limited to
wooden surfaces, rock surfaces, ceramic surfaces, synthetic
surfaces, etc. without limitation unless so indicated in the
following claims. The roof support structure 30' may engage an
upper portion of one or more pedestals 50 at the notches 37b'
formed in either side member 37a' of the roof support structure 30'
and at a top surface of the pedestal 50. After the pedestals 50 and
roof support structures 30' are properly positioned and engaged
with one another, one or more tiles 20 may be engaged with the roof
support structures 30', various aspects of which engagement are
described in further detail below. It is contemplated that the
pedestals 50 may be adjustable for height and slope to accommodate
variances in the structure, structural component, and/or surface to
which the pedestals 50 are engaged, and/or to provide a slope to
the tile 20 to adequately drain moisture from the tiles 20.
Illustrative Method of Use
[0082] Having described several preferred embodiments, an
illustrative method of using the tile and support structure 10 will
now be described. This method of use is not intended to limit the
scope of the present disclosure in any way, but is instead provided
for illustrative purposes only and may be applied and/or adapted to
suit various aspects of the present systems and/or components
thereof disclosed herein. Even though the foregoing illustrative
method of use is primarily adapted for decks 12, the scope of the
present disclosure is not so limited and a correlative method of
using the roof support structure 30' with or without pedestals 50,
and/or other systems and/or components within the spirit and scope
of the present disclosure will occur to those having ordinary skill
in the art in light of the present disclosure.
[0083] In one aspect, the tile and support structure 10 as
disclosed herein may he used to build a deck 12, wherein the tread
surface of the deck 12 may be comprised of the top faces 22 of the
tiles 20. Generally, the supporting surface for a deck 12 may be a
plurality of joists 14 arranged in a parallel fashion in a manner
similar to that shown in FIG. 1. The use of joists 14 herein are
for illustrative purposes only, and are in no way meant to be
limiting. Accordingly, other suitable structures, structural
components, surfaces and/or methods for forming a foundation and/or
underlying support for a deck 12 may be used without limiting the
scope of the present disclosure unless so indicated in the
following claims.
[0084] An edge support structure 30a may be engaged with the joists
14 adjacent one end of the joists 14 (e.g., the end of the joists
14 engaged with the building or other structure adjacent the deck
12). Generally, "edge support structure 30a" and "support structure
30" may be used interchangeably throughout this description of an
illustrative method of use. Accordingly, the scope of the present
disclosure related to a method of using any system and/or component
thereof disclosed herein is not limited by whether an edge support
structure 30a or support structure 30 is used unless so indicated
in the following claims. A support structure 30 may then be spaced
from the edge support structure 30 by a predetermined amount and
engaged with the joists 14 such that the position of the support
structure 30 is fixed with respect thereto. As previously
explained, a cross lathe may be positioned between the edge support
structure 30a and the joist(s) 14 and/or between the support
structure 30 and the joist(s) 14 if needed/desired.
[0085] The distance between the edge support structure 30a and the
support structure 30 may be dependent at least upon the
configuration of the tile 20 to be used with the deck 12, and more
specifically at least upon the distance between edges 24 of the
tile 20 having grooves 24a formed therein. Subsequent support
structures 30 may be engaged with the joists 14 at predetermined
distances from adjacent support structures 30 and/or edge support
structures 30a. Depending at least upon the configuration of the
tiles 20 to be used for the deck 12, the distance between adjacent
support structures 30 may be generally uniform for all support
structures 30 (e.g., for use with a deck 12 wherein most tiles 20
are generally of a similar shape), or some support structures 30
may be differently spaced with respect to adjacent support
structures 30 (e.g., for use with a deck 12 wherein a certain
number tiles 20 have different shapes). One end of the support
structures 30 may be left accessible and another end thereof may be
blocked and/or bound by another structure (which structure may
include but is not limited to a wall of a building, a deck frame,
joist 14 etc. unless so indicated in the following claims).
[0086] After the desired number of support structures 30 (and/or
edge support structures 30a) have been engaged with the joists 14,
a tile 20 may be positioned between adjacent support structures 30
(and/or between an edge support structure 30a and a support
structure 30). The tile 20 may be slid along the length of the
support structures 30 from an open end thereof to a blocked and/or
bound end thereof During this step, the rails 36 of the support
structure 30 may be positioned within the groove 24a formed in one
or more edges 24 of the tile 20. Another tile 20 may be slid along
the length of the same support structures 30 until the protrusions
24b on the edges 24 of the tiles 20 engage one another. Subsequent
tiles 20 may be positioned between other support structures 30
until a majority of the deck 12 is built.
[0087] In many instances it is contemplated that tiles 20
positioned on the periphery of the deck 12 may require cutting
and/or resizing due to various factors, including but not limited
to the shape of the periphery of the deck 12. Accordingly, after
all or a majority of the standard sized and/or shaped tiles 20 have
been properly positioned, specialized tiles 20 may be slid between
adjacent support structures 30 and/or edge support structures 30a.
After all desired tiles 20 have been properly positioned, the open
ends of the support structures 30 and/or end support structures 30a
may be blocked and/or bound by another structure (which structure
may include but is not limited to a wall of a building, a deck
frame, joist 14, specialized support structure 30 with suitable
aesthetics, etc. unless so indicated in the following claims).
[0088] It is contemplated that for some aspects and/or applications
it may be advantageous to use the tiles 20 to ensure that adjacent
support structures 30 are properly spaced from one another. In such
an embodiment, the support structures 30 may be engaged with a
joist 14 only at one end of the support structures 30. As tiles 20
are positioned between the support structures 30, a user may ensure
the proper position of the support structures 30 by placing a
lateral force thereon such that the tiles 20 are effectively
pinched between the support structures 30, at which point the
support structures 30 may be engaged with the joist(s) 14 adjacent
the most terminal tile 20. Those of ordinary skill in the art will
appreciate that this may be done in a. progressive manner. That is,
as each row of tiles 20 is slid between the support structures 30,
another fastener(s) 16 may be used to engage the support
structure(s) 30 with the joist(s) 14.
[0089] Those of ordinary skill in the art will appreciate that a
method similar to the immediately preceding method may be
extrapolated therefrom for use with a roof support structure 30'
such as those shown in FIGS. 13-16. In such a method, the pedestals
50 and roof support structures 30' may be engaged with a suitable
structure, structural component, and/or surface. The tiles 20 may
he slid along the length of the roof support structures 30' in a
manner similar to that as previously described.
[0090] Alternatively, one or more pedestals 50 for supporting a
first roof support structure 30' (which may constitute a roof edge
support structure 30a' and/or border) may be positioned on a
suitable structure, structural component, and/or surface. The
height of the pedestals 50 may he adjusted as desired, and a roof
edge support structure 30a' may be engaged with the pedestals 50.
The user may now secure another pedestal 50 or row of pedestals 50
in a manner generally parallel to the first roof support structure
30' but spaced apart therefrom and adjust the height of those
pedestals as desired. The user may engage a roof support structure
30' with the second pedestal 50 or row thereof At this point one or
more tiles 20 may be slide between the roof edge support structure
30a' and the roof support structure 30'. Alternatively, all the
required pedestals 50 and roof support structures 30' and/or roof
edge support structures 30a' may be properly positioned and secured
prior to installation of any tiles 20.
[0091] Those of ordinary skill in the art will appreciate that at
this point, the relative positions of the tiles 20, support
structures 30, and joists 14 generally may fixed in three
dimensions, but simultaneously incremental changes in those
relative positions may be allowed via flexing, bending, and/or
other allowed movement between one tile 20 and adjacent tiles 20,
between a tile 20 and support structures 30 engaged with the tile
20, and/or between a support structure 30 and the joist(s) 14 (or
other suitable structures, structural components, surfaces and/or
methods for forming a foundation and/or underlying support for a
deck 12) with which it is engaged. It is contemplated that at least
the configuration of the tiles 20 may affect the amount of
incremental changes in the above-referenced relative positions. It
is contemplated that a configuration allowing some or all of the
incremental changes in relative positions listed above may prevent
cracking and/or other damage to the tiles 20, which may be
manufacturing of a generally rigid, inflexible material.
Alternative Aspects of a Tile & Support Structure
[0092] Other aspects of a tile & support structure 10 employing
a retaining element 60 are shown in FIGS. 17A-17D. As shown
therein, a tile & support structure 10 may be configured for
use with a retaining element 60, various illustrative aspects of
which are shown in cross-section in FIGS. 17A-17D. Generally, it is
contemplated that a portion of the retaining element 60 may be
positioned in a groove 24a formed in an edge 24 of a tile 20 in a
manner analogous to that in which the rail 36 may be positioned in
a groove 24a as previously described herein for other aspects of a
tile & support structure 10.
[0093] It is contemplated that a tile & support structure 10
employing a retaining element 60 may be adapted for use in a
variety of applications using a variety of support structures 30
while simultaneously allowing relatively easy removal of a tile 20,
as further described below. Additionally, an aspect of a tile &
support structure 10 like those shown in FIGS. 17A-17D is that the
tiles 20 may be configured in an orientation other than straight,
such as curved, radiused, and/or an otherwise nonlinear fashion.
This configuration may be a result of one or more edge 24 of a tile
20 being curved, radiused, an/or otherwise non-linear without
limitation unless so indicated in the following claims. The tile
& support structure 10 shown in FIG. 17C may be especially
adapted for use in nonlinear tile 20 configurations, but other tile
& support structures 10 may be configured for nonlinear tile 20
configurations without limitation unless so indicated in the
following claims.
[0094] Referring now to FIG. 17A, which provides a cross-sectional
view of a tile & support structure 10, wherein the support
structure 30 may be configured as an extruded rail-like structure
having a base 31 with a generally planar upward-facing surface.
Generally, it is contemplated that one or more tiles 20 may rest
upon the generally planar upward-facing surface of the base 31. The
support structure 30 may be configured in a manner that is somewhat
similar to a bottom portion or rail portion 37' of the roof support
structures 30 shown in FIGS. 13-16, wherein the support structure
30 may include one or more side members 37a' having a notch 37b'
formed in a side member 37a', and wherein the side members 37a' may
extend downward from the base 31. Additionally, one or more bottom
members 37c' may be engaged with the bottom edge of either side
members 37a' in a manner analogous to that previously described
with respect to FIGS. 15A & B without limitation unless so
indicated in the following claims.
[0095] The support structure 30 may be formed with various walls,
supports, channels, angles, and/or other features therein to
provide the required rigidity and/or structural integrity for the
specific application of the tile & support structure 10. A
support structure 30 such as that shown in FIG. 17A may be engaged
with one or more joists 14 in an elevated deck application, with a
fiat floor and/or sub-floor structure, a flat roof and/or sub-roof
structure, and/or any other suitable structures, structural
components, and/or surfaces without limitation unless so indicated
in the following claims.
[0096] The support structure 30 may be formed with one or more
anchors 38, which anchor(s) 38 may be configured to securely engage
a portion of a fastener 16. The fastener 16 may engage the
retaining element 60 such that the relative positions of the
fastener 16 and retaining element 60 are fixed with respect to one
another. Alternatively, the fastener 16 may engage the retaining
element 60 such that the retaining element 60 may rotate with
respect to the fastener 60. Still further, the fastener 16 may
engage the retaining element 60 such that the retaining element 60
may move longitudinally along the axis of the fastener 16 (but not
radially with respect to the longitudinal axis of the fastener 16),
which movement may be allowed alone or in conjunction with rotation
of the retaining element 60 with respect to the fastener 16.
Accordingly, the scope of the present disclosure is not limited by
the relative movement between the fastener and retaining element 60
unless so indicated in the following
[0097] The retaining element 60, 60' may include a neck 62, 62',
which may be integrally formed with retaining element 60, 60'. The
neck 62, 62' may provide a limit to the distance into a support
structure 30 or other suitable structure, structural component,
and/or surface that a fastener 16 associated with the retaining
element 60, 60' may penetrate. The optimal length of the neck 62,
62' may vary from one application of the tile & support
structure 10 to the next without limitation unless so indicated in
the following claims. However, it is contemplated that in some
applications it may be advantageous to configure the length of the
neck 62, 62' to be approximately equal to the thickness of the
substrate 18 adjacent the groove 24a. It is contemplated that such
a configuration may ease installation of a tile 20 by providing a
type of automatic stop for the depth of a fastener 16 associated
with a retaining element 60, 60', such that the exposed side of the
retaining element 60, 60' may be relatively easily engaged with the
groove 24a in another tile 20.
[0098] Referring now to FIGS. 17A-17C, a portion of the retaining
element 60 may be positioned in the groove 24a formed in the edges
24 of two adjacent tiles 20. It is contemplated that the retaining
element 60 may be formed as a circle, an oval shape, or any other
suitable shape without limitation unless so indicated in the
following claims. For the tiles 20 and support structures 30
positioned at the borders, the retaining elements 60 may be
configured such that the retaining elements 60 are asymmetrical in
shape. Various aspects of a retaining element 60' that may be used
on a border are shown in FIG. 18. That retaining element 60' may be
configured to engage only one groove 24a in one tile 20 on a single
side of the retaining element 60' as opposed to a retaining element
60 configured to engage a groove 24a in each of two adjacent tiles
20 on either side of the retaining element 60.
[0099] As shown in FIGS. 17A-17C, the anchor 38 may be configured
as a threaded aperture and the fastener 16 may be configured as a
screw and/or bolt with threads corresponding to those formed in the
anchor 38. In an aspect, the threaded portion of the fastener 16
may pass through an aperture in the retaining element 60 and engage
the anchor 38, thereby selectively securing the relative positions
of the fastener 16, support structure 30, the retaining element 60,
and the tiles 20 with grooves 24a in which the retaining element 60
is positioned. Alternatively, the various components may be
configured such that after the threaded portion of the fastener 16
has passed through an aperture in the retaining element 60 and
engaged the anchor 38, the tile(s) 20 with grooves 24a in which the
retaining element 60 is positioned may be immobilized save for a
dimension that is collinear with the length of the groove 24a for a
specific tile 20. That is, the retaining element 60 and underlying
support structure 30 may be configured such that tiles 20 may slide
with respect to the retaining element 60 and support structure 30
during installation of the tile(s) 20, but such that after
installation the relative positions of the retaining element 60 and
support structure 30 are generally fixed with respect to the
position of the tile(s) 20 in three dimensions. One or more
retaining elements 60 may be configured such that in conjunction
with an underlying structure (such as a support structure 30 or
other suitable structures, structural components, surfaces) the
retaining elements 60 prevents and/or mitigates uplift of one or
more tiles 20 due to wind, prevents and/or mitigates unauthorized
removal of a tile 20, and/or prevents and/or mitigates unwanted
movement of the tile 20. It is contemplated that one or more
retaining elements 60 may provide various benefits without the need
for adhesive while simultaneously providing adequate securement of
one or more tiles 20.
[0100] The width of the retaining element 60 and the width of the
fastener 16 may be selected such that a clearance 25 exists between
the edges 24 of adjacent tiles 20, wherein the clearance 25 is wide
enough to allow access for selective removal of the fastener 16 by
extending a tool (such as a screwdriver in one aspect) into the
clearance 25 and engaging the tool with the fastener 16 to
disengage the fastener 16 from the support structure 30.
Alternatively, the tool may be extended into the clearance 25 and
engage the fastener 16 to tighten the fastener 16 and/or engage the
fastener 16 with the support structure 30. Accordingly, in an
aspect a tile & support structure 10 utilizing retaining
elements 60 as disclosed herein to secure the position of one or
more tiles 20 with respect to a support structure 30, a user may
selectively remove one or more tiles 20 singularly without removing
unwanted tiles 20 and without cutting, breaking and/or otherwise
altering the support structure 30 and/or tiles 20. It is
contemplated that the ability to selectively remove one tile 20 at
a time may be especially advantageous if one or more tiles 20
restrict access to certain items, such as ventilation ducts,
electrical wiring, plumbing, etc.
[0101] Referring now to FIG. 17B, which shows a support structure
30 as it may be engaged with a joist 14, the tile & support
structure 10 may be employed in a raised-deck application. It is
contemplated that the tile & support structure 10 shown in FIG.
17A may provide the various benefits of other tile & support
structures 10 disclosed herein, but which may be specifically
adapted for use in a raised-deck application. The support structure
30 may be formed with one or more apertures 32b therein to provide
a channel though which a fastener 16 may pass, which fastener 16
may be used to secure the support structure 30 to one or more
joists 14 (or other suitable structure, structural component,
and/or surface without limitation unless so indicated in the
following claims).
[0102] Referring now to FIGS. 17A and 17B, it is contemplated that
a plurality of tiles 20 may be installed using a retaining element
30 in a manner similar to that of installing tongue-and-groove
coverings (e.g., flooring, ceilings, etc.). However, the scope of
the present disclosure is not limited by the specific method of
installation unless so indicated in the following claims. Still
referring to FIGS. 17A and 17B, it is contemplated that for
installation, a user may first secure a support structure 30 on a
border, and then secure a second support structure 30 parallel to
but spaced apart from the border support structure 30. The user may
then install a row of tiles 20 with retaining elements 60'
configured for border tiles 20 on the outer edge 24 of the tiles
20, wherein a fastener 16 associated with those retaining elements
60' may engage anchors 38 formed in the border support structure
30, and wherein a portion of the retaining element(s) 60' may be
positioned in a groove 24a formed in the outer edge 24 of the
border tile 20. The tile(s) 20 on either end of the row may be
prevented from moving in at least two dimensions e.g., the two
horizontal dimensions) by a wall, baseboard, or other structure
adjacent the row of tiles 20.
[0103] The user may then install retaining elements 60 on the inner
edge 24 of the border tiles 20, wherein a fastener 16 associated
with those retaining elements 60 may engage anchors 38 formed in
the second support structure 30 that is adjacent to but spaced from
the border support structure 30, and wherein a portion of the
retaining element(s) 60 may be positioned in a groove 24a formed in
the inner edge 24 of the border tile 20 (which inner edge 24 may
rest on the second support structure 30). The optimum number of
retaining elements 60, 60' engaged with a given tile 20 will vary
from one application of the tile & support structure 10 to the
next, and may be dependent at least upon the size of a tile 20, the
number of tiles 20, and/or the elevation of the tile 20 from ground
level. In an aspect, four retaining elements 60, 60' positioned
approximately adjacent four corners of a tile 20 may be used to
adequately fix the relative position of the tile 20. However, other
numbers and/or relative positions of retaining elements 60. 60' may
be used without limitation unless so indicated in the following
claims, and the optimal number and/or relative positions may depend
at least on the size and/or shape of the tile(s) 20.
[0104] At this point, the user may secure a third support structure
30 adjacent the second support structure 30 in an orientation that
is parallel to but spaced from the second support structure 30. It
is contemplated that for some applications, the distance between
adjacent support structures 30 may be equal, while in other
applications the distance between adjacent support structures 30
may vary at least depending on the uniformity of the size and/or
shape of tiles 20 used therewith. Additionally, for certain
applications it is contemplated that one or more of the support
structures 30 may be radiused, curved, and/or otherwise non-linear.
Accordingly, the scope of the present disclosure is in no way
limited by the specific distance between adjacent support
structures 30 or whether such support structures 30 are linear or
non-linear unless so indicated in the following claims.
[0105] The user may place a first edge 24 of another tile 20 on the
second support structure 30 such that a portion of the exposed
retaining element(s) 60 slides into the groove 24a on the first
edge 24 of the tile. A second edge 24 of the tile 20 that is
parallel to but opposite of the first edge 24 may be placed on the
third support structure 30 and one or more retaining elements 60
may be positioned in a groove 24a on the second edge 24, and the
position of those retaining elements 60 relative to the tile 20 and
third support structure 30 may be secured via engaging a fastener
16 with those retaining elements 60 and the third support structure
30. This process may continue until the desired number of tiles 20
are positioned on the support structures 30, at which time one or
more retaining elements 60' may be engaged with a subsequent border
support structure(s) 30 to secure the relative position of one or
more subsequent border tiles 20. Because the support structures 30
may be configured as elongate, straight extrusions, it is
contemplated that installation may be relatively expeditious.
[0106] Referring now to FIG. 17C, which shows various aspects of a
tile & support structure 10 that may be configured for use with
one or more laths 19 (which laths 19 include but are not limited to
those constructed of wood unless so indicated in the following
claims). It is contemplated that the method of installing a tile
and support structure 10 such as that shown in FIG. 17C may be
analogous to the method for the tile and support structure 10 shown
in FIGS. 17A and 17B, wherein laths 19 are used in place of support
structures 30. Accordingly, fasteners 16 associated with a
retaining element 60, 60' may directly engage the lath 19, and the
lath 19 may have predrilled holes for accepting fasteners 16, or
the lathe 19 may be used without predrilled holes.
[0107] The optimal configuration (length, threads, diameter, etc.)
of the fastener 16 associated with the retaining element 60, 60'
may vary from one application of the tile & support structure
10 to the next, and may depend at least upon the configuration of
the support structure 30 and/or other suitable structure,
structural component, and/or surface to which the fastener 16 is
secured during use. In another aspect, and without limitation
unless so indicated in the following claims, the fastener 16 may be
configured to engage a roof support structure 30', such as those
shown in FIGS. 13-16B. In a specific illustrative example, a
fastener 16 configured to engage a lath 19 may be configured with
threads that are coarser and/or having a longer threaded portion
than those on a fastener 16 configured to engage an anchor 38 in a
support structure 30. Accordingly, the specific configuration of
the fastener 16 in no way limits the scope of the present
disclosure unless so indicated in the following claims.
[0108] The retaining elements 60, 60' may be constructed of any
suitable material, including but not limited to metals, plastics,
polymers, natural materials, and/or combinations thereof without
limitation unless so indicated in the following claims.
Additionally, it is contemplated that the thickness of a retaining
element 60, 60' may optimally be slightly less than the thickness
of the groove 24a in the edge 24 of a tile 20 for which the
retaining element 60, 60' is designed, and that the shape may be
any suitable shape (e.g., square, oblong, circular, rectangular,
etc). Accordingly, the retaining elements 60, 60' may be formed
with any different thicknesses and/or shapes without limitation
unless so indicated in the following claims.
Alternative Aspects of a Support System and Pedestal
[0109] Referring now to FIGS. 19A-23B, an aspect of a support
structure 30 may include a pedestal 50. Such a support structure 30
may be configured as a roof support structure 30', but may also be
configured for use with a deck, elevated patio, and/or any other
surface without limitation unless so indicated in the following
claims. It is contemplated that in an aspect, all or a portion of
the support structure 30 may be engaged with a pedestal upper
surface 54, which may be positioned opposite a pedestal base 52. As
with other aspects of pedestals 50 previously described herein, it
is contemplated that the pedestal base 52 may be engaged with an
underlying supporting structure and/or surface, including but not
limited to concrete unless so indicated in the following claims.
Accordingly, any or other suitable structure, structural component,
and/or surface may be used, including but not limited to wooden
surfaces, synthetic surfaces, metallic surfaces, etc. without
limitation unless so indicated in the following claims.
[0110] In an aspect, it is contemplated that a pedestal 50 may be
adjustable for height via an adjustment portion 53 (which may be
positioned between the pedestal base 52 and pedestal upper surface
54) and/or slope to accommodate variances in the structure,
structural component, and/or surface to which the pedestals 50 are
engaged and/or to provide a slope to the tile 20 engaged with the
pedestal 50 so as to adequately drain moisture from the tiles 20.
Further, it is contemplated that in an aspect all or a portion of
what would constitute the support structure 30 may be integrally
formed with a portion of the pedestal 50, such as the pedestal
upper surface 54, as further described in more detail below.
However, the scope of the present disclosure is not so limited
unless so indicated in the following claims. For purposes of
clarity, the term "pedestal 50" as used when referring to FIGS.
19A-23B may be used in a manner that is inclusive of the support
structure 30.
[0111] As shown, a pedestal 50 may be configured with one or more
spines 34 extending from a pedestal upper surface 54. In an aspect
shown at least in FIGS. 19A-22A, one or more spines 34 may extend
upward from the pedestal upper surface 54 along and/or adjacent to
a diameter of the pedestal upper surface. In an aspect of a
pedestal 50 shown at least in FIGS. 19A-22B, this diameter may be
collinear with a diameter of the pedestal base 52 and/or adjustment
portion 53. That is, in one aspect a common line may pass through
the geometric center point of the pedestal upper surface 54, the
geometric center point of the adjustment portion 53, and/or the
geometric center point of the pedestal base 52. In an aspect, as
many as four spines 34 may extend from a single pedestal upper
surface 54, various aspects of which are shown in FIG. 22B, or as
few as one spine 34 may extend from a single pedestal upper surface
54, various aspects of which are shown in FIGS. 19A, 19B, and
21.
[0112] The spines 34 may be configured such that the four spines 34
comprise two pairs of collinear spines 34 (which configuration is
shown at least in FIG. 22B), wherein the two pairs may be
perpendicular with respect to one another and positioned along
diameters of the pedestal upper surface 54 intersecting one another
at a right angle. The spines 34 may extend all the way to the
center point of the pedestal upper surface 54 as shown in FIGS. 22A
and 22B, or the spines 34 may extend only part way between the
periphery of the pedestal upper surface 54 and the center point of
the pedestal upper surface 54 (as shown in FIGS. 9A-20B).
Accordingly, the distance along the pedestal upper surface 54 that
a given spine 34 extends in no way limits the scope of the present
disclosure unless so indicated in the following claims.
[0113] In another aspect shown at least in FIGS. 19A, 19B, and 21,
one spine 34 may extend from a pedestal upper surface 54 along a
first diameter thereof. In still another aspect shown at least in
FIGS. 20A and 20B, two spines 34 may extend from the pedestal upper
surface 54, wherein a first spine 34 may be positioned on a first
diameter of the pedestal upper surface 54 and a second spine 34 may
be positioned on a second diameter of the pedestal upper surface
54, wherein the first and second diameters may be perpendicular
with respect to one another. In still a further aspect, two spines
34 may extend upward from the pedestal upper surface 54 along a
first diameter thereof, wherein a first spine 34 may be positioned
on an opposite side of the center point of the pedestal upper
surface 54 with respect to a second spine 34. Accordingly, the
specific number, orientation, and/or configuration of spines 34
extending from a pedestal upper surface 54 in no way limits the
scope of the present disclosure unless so indicated in the
following claims.
[0114] At the top distal end of the spine 34, two corresponding
rails 36 may extend outward from the spine 34 in a generally
horizontal dimension. In this aspect, the spine 34 and rails 36 may
correspond directly to the spine 34 and/or rail(s) 36 previously
described regarding aspects of a support structure 30 in FIGS.
4-12C and/or to the spine 34' and rail(s) 36' previously described
regarding aspects of a roof support structure 30' in FIGS. 13-16B.
However the spine 34 and/or rail(s) 36 may be differently
configured without limitation unless so indicated in the following
claims.
[0115] In certain applications, it may be advantageous to construct
the pedestal 50, spine 34, and/or rails) 36 of a plastic, polymer,
or other synthetic material, or of a metal or metallic alloy.
However, those elements may be constructed of any suitable
material, including but not limited to plastic, polymers, natural
materials, metals and their alloys and/or combinations thereof
without limitation unless so indicated in the following claims.
Additionally, in certain applications it may be advantageous to
construct the pedestal 50 (and/or a portion thereof, such as the
pedestal upper surface 54) integrally with the spine 34 and/or
rails) 36, or it may be advantageous to construct certain portions
separately and later join them together.
[0116] It is contemplated that in one aspect, the pedestal upper
surface 54 may be removably engaged with another portion of the
pedestal 50, such as a top part of the adjustment portion 53. For
example, Eurotec, GmbH in Germany manufactures adjustable pedestals
having an upper part, a threaded ring, an extension ring, and a
baseplate as shown on page 5 of Appendix A. As mentioned above
regarding a "click adapter," different adapters may be selectively
engaged with the upper part of the pedestal to provide a modular
system, as shown in page 6 of Appendix A. In an aspect, the
spine(s) 34 and/or rail(s) 36 may be formed on another adaptor for
selective engagement with the upper part to make a pedestal 50 with
a support structure 30 therein, which may share aspects with the
pedestals 50 and support structures 30 shown in FIGS, 19A-23B. It
is contemplated that the pedestal upper surface 54 (when using a
pedestal such as that shown in Appendix A) may comprise a portion
of the upper part (as shown on page 5 of Appendix A) and a portion
of an adaptor formed with one or more spines 34 and one or more
rails 36. Accordingly, the scope of the present disclosure is not
limited by whether the pedestal 50 having one or more spines 34 and
one or more rails 36 is comprised of a separate pedestal portion
and a selectively removable adaptor portion (on which adaptor
portion the spinets) 34 and rails) 36 are formed), or if the
spinets) 34 and rail(s) 36 are integrally formed with the pedestal
50 itself, thereby foregoing the requirement of a separate adapter
portion unless so indicated in the following claims. Accordingly,
the scope of the present disclosure is not limited by whether the
various portions of a pedestal 50, spine(s) 34, and/or rail(s) 36
engaged therewith are integrally formed with one another or
separately formed and later engaged with one another unless so
indicated in the following claims.
[0117] As previously described in detail above, opposite edges 24
of a tile 20 may be formed with a groove 24a therein, as shown in
FIGS. 10, 12A, and 12B. The groove 24a may be formed in the edge 24
of the tile 20, in a portion of the edge 24 of the tile 20, in a
portion of a surface of a substrate 18 (if present), and/or a
combination of a portion of the tile 20 and a portion of the
substrate 18 without limitation unless so indicated in the
following claims. The groove 24a may he configured such that it
cooperates with the rail 36 at the top distal end of the spine 34,
and such that the bottom face 22 of the tile 20 (or bottom surface
of the substrate 18, if present for that embodiment of a tile 20)
rests upon the pedestal upper surface 54. Again, the pedestal upper
surface 54 may he comprised of a portion of the adaptor and a
portion of the upper part of the pedestal if a pedestal and
corresponding adaptor such as that shown in pages 5 and 6 of
Appendix A is employed. The configuration (e.g., size, dimensions,
shape) of the pedestal upper surface 54, spine 34, and/or rails 36
may Vary from one application of the tile and support structure 10
to the next, and may vary depending at least upon the size, shape,
and weight of the tile(s) 20 engaged with the pedestal upper
surface 54. In one aspect, it may be advantageous to configure the
pedestal upper surface generally in a circular shape having a
diameter of between 4 and 16 inches in diameter. However, the scope
of the present disclosure is not so limited unless indicated in the
following claims. This configuration may be especially useful in
preventing wind uplift for tiled surfaces (e.g., deck, patio, roof
surfaces, etc. without the need for elongate support structures 30
such as those previously described and shown in FIGS. 2-7. Instead,
pedestals 50 configured with one or more spines 34 and one or more
rails 36 may be strategically positioned to support a plurality of
tiles 20 as described in further detail below (which strategic
positioning may be adjacent one or more corners of a tile 20
without limitation unless so indicated in the following
claims).
[0118] In an aspect, the pedestal 50 shown in FIGS. 19A and 19B and
the pedestal 50 shown in FIG. 21 may be used to support two tiles
20, wherein one rail 36 corresponds to each tile 20. In an aspect,
each rail 36 may be positioned adjacent a corner of the tile 20
during use. However, in other aspects the rail 36 may be positioned
on an interior portion of the tile 20 as described below.
Accordingly, the optimal position along the edge 24 of a tile 20 at
which a rail 36 engages the tile 20 may vary from one application
of the present disclosure to the next, and is therefore in no way
limiting to the scope of the present disclosure unless so indicated
in the following claims. As previously described, it is
contemplated that a rail 36 may optimally engage a tile 20 at a
groove 24a formed in an edge 24 of the tile 20.
[0119] In an aspect of the pedestal 50 shown in FIG. 22A, the
pedestal 50 may be used to support two tiles 20 positioned on
either side of the spine 34. Alternatively, the pedestal 50 shown
in FIG. 22A may be used to support four tiles 20, wherein corners
of adjacent tiles 20 may be offset from one another, or wherein
corners of adjacent tiles 20 may be positioned adjacent one another
at or around the center point of the pedestal upper surface 54. In
such a configuration, at least one edge 24 of a tile 20 may not
require a groove 24a formed therein, as that edge 24 of a tile 20
may directly abut an edge 24 of an adjacent tile 20. It is
contemplated that each rail 36 may be positioned at any point along
the length of the tile 20, wherein a tile 20 may be positioned on
either side of the spine 34. In an aspect, the spine 34 may extend
along the entire width and/or length of the pedestal upper surface
54 (as depicted in at least FIG. 22A), or the spine 34 may extend
along only a portion of the pedestal upper surface 54 (as depicted
at least in FIGS. 19A-20B) without limitation unless so indicated
in the following claims.
[0120] Referring now specifically to FIG. 22B, which provides a top
view of a pedestal 50 having two pairs of collinear spines 34,
wherein the two pairs may be perpendicular with respect to one
another and positioned along diameters of the pedestal upper
surface 54, the pedestal 50 may be configured to simultaneously
engage up to four tiles 20. It is contemplated that the pedestal 50
depicted in FIG. 22B may optimally engage each tile 20 at or
adjacent to the corner thereof. Grooves 24a formed in perpendicular
edges 24 that intersect one another on a single tile 20 may by
engaged with rails 36 extending toward the respective edges 24 from
spines 34 that are oriented perpendicular with respect to one
another (and parallel with respect edges 24 of the tile 20). The
opposite rails 36 engaged with those spines 34 may engage grooves
24a formed in a second and a third tile 20, respectively, and other
grooves 24a in the second and third tiles 20 may be engaged with
other rails 36 extending from additional spines 34, respectively.
Accordingly, in light of the present disclosure it will be apparent
to those skilled in the art that the pedestal shown in FIG. 22B may
simultaneously engage up to eight grooves 24a formed in eight
respective edges 24 of four respective tiles 20 via eight
respective rails 36 configured as pairs extending from four
respective spines 34. However, the scope of the present disclosure
is not so limited unless so indicated in the following claims.
[0121] In an aspect of the pedestals 50 shown in FIGS. 23A and 23B,
the pedestal base 52 may be offset from the spine 34, adjustment
portion 53, and/or pedestal base 52. It is contemplated that
pedestals 50 and/or spines 34 so configured may be especially
useful at an edge or border of a tiled surface, such as adjacent a
wall or edge of a roof Again, a rail 36 extending outward from the
spine 34 may engage a groove 24a formed in respective edges 24 of
tiles 20. However, the scope of the present disclosure is not
limited by the relative position of one pedestal 50 with respect to
another and/or the number of tiles 20 engaged with a given pedestal
50 unless so indicated in the following claims.
[0122] Referring specifically to FIG. 23A, the pedestal 50 may be
used to engage up to two tiles 20 at adjacent corners of those
tiles 20. As with various other pedestals 50 disclosed herein, it
is contemplated that a corner of a tile 20 may be positioned
adjacent the intersection of two perpendicular spines 34. The
pedestal 50 may be configured such that a first spine 34 along a
straight edge of the pedestal upper surface 54 includes one rail 36
extending outward therefrom toward the center of the pedestal upper
surface 54 and a second spine perpendicular to the first spine 34
includes two rails 36 extending outward thereform. The rail 36 on
the first spine 34 may engage grooves 24a on collinear edges 24 of
the two adjacent tiles 20. Each rail 36 of the second spine 34 may
engage parallel grooves 24a formed in parallel edges 24 of those
tiles 20 (which parallel edges 24 may he perpendicular to the
collinear edges 24). However, other configurations of spines 34,
rails 36, and/or tiles 20 may be used without departing from the
scope of the present disclosure unless so indicated in the
following claims.
[0123] Referring specifically to FIG. 23B, the pedestal 50 may be
used to engage up to two tiles 20 at adjacent corners of those
tiles 20 via a single rail 36 extending from a single spine 34 in a
direction toward the center point of the pedestal upper surface 54,
wherein corners of adjacent tiles 20 may be adjacent. In such a
configuration, at least one edge 24 of a tile 20 may not require a
groove 24a formed therein, as that edge 24 of a tile 20 may
directly abut an edge 24 of an adjacent tile 20 (e.g., the edges 24
oriented perpendicular with respect to the spine 34).
Alternatively, the pedestal 50 may he used to engage a single tile
20 along a given groove 24a formed in an edge 24 thereof, such that
all or a portion of the rail 36 is positioned in a single groove
24a of a single tile 20. The rail 36 may be positioned at any point
along the length of the tile(s) 20, and the spine 34 may constitute
a border or periphery of the tiled surface in a manner similar to
that previously described with respect to the pedestal 50 shown in
FIG. 23A.
[0124] In an aspect, the spine 34 may be positioned along a
straight edge of the pedestal upper surface 54. However, in another
aspect, the spine 34 and/or rails) 36 may be curved, contoured,
and/or non-linear so as to follow a curved, contoured, and/or
non-linear edge 24 of a particular tile 20. Accordingly, the
specific orientation and/or configuration of a tile 20 or tiles 20,
pedestal 50, pedestal base 52, pedestal upper surface 54, spine 34,
and/or rail(s) 36 for any illustrative aspects of a pedestal 50,
spine 34, and/or rail(s) 36 in no way limits the scope of the
present disclosure unless so indicated in the following claims.
[0125] Generally, a tiled surface (e.g., roof, deck, patio, etc.)
may be constructed using pedestals 50 such as those shown in FIGS.
19A-23B using a method similar to those previously described herein
for the support structures 30, roof support structures 30', and/or
support structures 30 in conjunction with a retaining element 60.
Alternatively, in an aspect of a pedestal 50 having an adapter
portion configured with one or more spines 34 and one or more rails
36, the pedestal bases 52 may be secured and arranged in a desired
manner first Next, rails 36 of corresponding adapters may be
engaged with grooves 24a of a tile 20 such that the relative
positions of the adapters correspond to relative positions of the
pedestal bases 52, and such that the adapter(s) and corresponding
tile 20 may be lowered simultaneously until the adaptors) engages
the pedestal(s) 50 (which engagement may be primarily at the
pedestal upper surface 54 and/or adjacent portion) and the tile 20
is supported by the pedestal(s) 50. However, the feasibility of
such a method of constructing a tiled surface may depend on the
specific configuration of the spines 34 and/or rails 36 on the
adapter, and specifically may depend at least on the number of
tiles 20 that the adapter is configured to engage, the position on
the edge 24 that the tile 20 engages the groove 24a, and/or the
shape of the tile 20 without limitation unless so indicated in the
following claims.
[0126] The pedestals 50, spine(s) 34, and/or rail(s) 36 may be
configured such that the position of a tile 20 relative to the
position of a pedestal 50 and/or the position of another tile 20
may be fixed in one dimension, two dimensions, or three dimensions
without limitation unless so indicated in the following claims. In
an aspect, one or more spines 34 and/or rails 36 may cooperate with
one or more adjacent tiles 20 to fix the relative position of a
tile 20 with respect to one or more pedestals 50 and/or other tiles
20 without limitation unless so indicated in the following claims.
Additionally, the pedestals 50 shown in FIGS. 19A-23B (and/or
pedestals 50 providing similar features, functionality, and/or
benefits thereto may be used with one another, with a support
structure 30, and/or with a roof support structure 30' similar to,
or with aspects that are correlative to, that shown in FIGS. 2-9,
11A-12C, and/or 14-16B, and/or a retaining element 60, 60' similar
to that shown in FIGS. 17A-18 without limitation unless so
indicated in the following claims.
Reinforced Tiles
[0127] For certain applications (e.g., raised patios or walkways,
rooftops, etc.) it may be desirable to elevate a tile (e.g., a
ceramic or porcelain tile) for an underlying support structure.
Most often tiles are elevated from such a structure using a
plurality of pedestals. Generally, tiles that are elevated from an
underlying support structure may be required to exhibit additional
strength as compared to non-elevated tiles. Previously, tile
manufacturers would allow a standard tile to be installed in an
application wherein the tile was elevated up to four inches above
the underlying support structure. The tile manufacturer would
provide disclaimers for any height greater than four inches and
recommend a backed tile for such applications. More recently, tile
manufacturers are including this disclaimer and associated
recommendation for tiles that are elevated as little as 0.75 inches
or more from a solid surface, since such tiles may be required to
exhibit a minimum strength and/or shatter resistance so that they
do not break under load, shatter due to impact, break due to wind
uplift, and/or otherwise fail to perform as designed and/or cause
any type of safety risk.
[0128] In elevated applications the tiles are required to exhibit a
minimum strength so that they do not break when under load. Various
pedestals and installation instructions for such pedestals and
raised tiles are shown in Appendix C, which is attached hereto and
made a part hereof. Among other disadvantages, prior art tiles,
including those having a galvanized metal backer, may be more
costly, have a shorter lifespan (particularly in ocean breeze or
wet climates), and may make additional, unwanted noise when
installed using various types of rooftop pedestals and/or metal
fasteners. Specifically for tiles including a galvanized metal
backer, such products typically only include a five-year warranty,
weigh from 9 to 19 pounds per tray (depending on thickness), can
lead to significant discoloration and staining issues, and are
often configured as peel-and-stick backers such that the installed
is responsible for adhering the galvanized material to the
tile.
[0129] A peel-and-stick backer assembled on site may exhibit
additional disadvantages, such as a requirement that the work area
and materials remain clean and dry (which may be extremely
difficult on a construction site where tiles are cut with wet tile
saws generating dust and constant water flow). Additionally, tiles
with galvanized backers are typically only available in
24-inch.times.24-inch and 24-inch.times.28-inch nominal sizes,
whereas most tile manufacturers make tiles in other sizes, such as
12-inches.times.48-inches, 36-inches.times.36-inches,
12-inches.times.24-inches, 8-inches.times.48-inches, etc. By
contrast, the reinforced tile 120 disclosed herein may be
configured in any size and/or shape such that it may be used in
virtually any application, including but not limited to decking,
roofing, raised decks, stairs, etc. without limitation unless
otherwise indicated in the following claims. The reinforced tile
120 disclosed herein may also be configured with a custom shape, as
a wood-look plank tile, as a modular tile, etc. without limitation
unless otherwise indicated in the following claims.
[0130] Many porcelain tile suppliers include various disclaimers
when marketing/selling their products, wherein the disclaimers may
state that if the porcelain tile is raised off the ground that it
should be reinforced to avoid shatter and/or fall-through injury or
damage liability. Previously these disclaimers indicated that
reinforcement should be used if the tile was four inches or more
above a solid surface, but as indicated above, that threshold has
been lowered to 0.75 inches or more above a solid surface. It is
contemplated that the stricter guidelines for reinforcement is a
result of improper use of landscaping payers being used with
pedestals, decks, and/or other raised surfaces, which may create
shatter concerns, wind up-lift problems, shorter lifespan of
product, and/or liability issues among other problems without
limitation unless otherwise indicated in the following claims.
[0131] Applicant has found through testing that adhering a
substrate 120a to one side of a tile to create a reinforced tile
120 greatly increased the breaking strength and/or shatter
resistance of the reinforced tile 120 compared to the prior art
tile. Generally, the substrate 120a may be adhered to the back or
bottom side of the tile to create a reinforced tile 120, but the
scope of the present disclosure is not so limited unless otherwise
indicated in the following claims As used in this portion of the
disclosure, the term "tile" may be used to refer to the portion of
the reinforced 120 that does not include the substrate 120a, which
portion may be constructed of any suitable material including but
not limited to porcelain, stone, cement, concrete, and/or
combinations thereof without limitation unless otherwise indicated
in the following claims.
[0132] Generally, Applicant has found that adhering a substrate to
one side of a tile to create a reinforced tile 120 may allow the
reinforced tile 120 to meet deck dead and/or live loading codes,
eliminate shatter and/or fall-through risk, and/or provide other
benefits without limitation unless otherwise indicated in the
following claims. Such risks are present in the prior art when
prior art tiles are used in an elevated application (e.g., with
pedestals, elevated decks, etc.) without limitation unless
otherwise indicated in the following claims. Generally, it is
contemplated that the substrate 120a may be configured as a
pultruded fiberglass plate and may he configured as having a
generally uniform thickness and material properties at various
portions thereof. It is further contemplated that a substrate 120a
so configured may provide predictable, consistent material
properties for the reinforced tile 120, but the scope of the
present disclosure is not so limited unless otherwise indicated in
the following claims. Through testing Applicant has found that the
breakage values, strength, and/or shatter resistance of reinforced
tiles 120 constructed according to the present disclosure are much
higher than those of tiles of the prior art, including but not
limited to those that use fiberglass mesh or galvanized metal
backers.
[0133] In an illustrative embodiment, the tile that may be used to
create a reinforced tile 120 may be a standard ceramic, porcelain,
or otherwise rigid tile. The materials of construction, size, and
shape of the tile may vary depending on the specific application of
the reinforced tile 120 and is therefor in no way limiting to the
scope of the present disclosure unless otherwise indicated in the
following claims. In one illustrative embodiment the tile by be 12
inches wide, 12 inches long, and 2 cm thick. In another
illustrative embodiment the tile may be 10 inches wide, 10 inches
long, and 14 mm thick. .Again, the scope of the present disclosure
is in no way limited by the dimensions of the tile and/or substrate
120a used to create the reinforced tile 120 unless otherwise
indicated in the following claims.
[0134] In an illustrative embodiment, the substrate 120a that is
adhered to the tile may be a fiberglass reinforced product or
similar solid composite in varying thickness applied to the surface
of the tile with a chemical adhesive (e.g., epoxy, glue, or another
long-lasting adhesive). Through testing it has been found that a
reinforced tile 120 exhibits dramatic increases in strength and/or
shatter resistance compared to the substrate 120a alone or the tile
alone. In other embodiments of the reinforced tile 120 the
substrate 120 may be configured as a material other than
fiberglass, as described in further detail below and without
limitation unless otherwise indicated in the following claims.
[0135] Results of a first test and the details of the testing
procedure are shown in Appendix D, which is attached hereto and
made a part of this disclosure. A porcelain tile that was 24 inches
wide, 24 inches long, and 20 mm thick was cut to be 12 inches wide
and 12 inches long. A 1/4-inch thick substrate 120a comprised of
Extren 500 series was cut to 12 inches by 12 inches and adhered to
one side of the porcelain tile. A technical data sheet for this
substrate 120a, which is a pultruded fiberglass product sold by
Strongwelll Corp., is shown in Appendix G, which is incorporated by
reference herein and made a part of this disclosure. Ten reinforced
tiles 120 were tested according to ASTM C648 "Standard Test Method
for Breaking Strength of Ceramic Tile" and exhibited an average
breaking strength of 3226 lbf, with the lowest being 2702 lbf and
the highest being 3654 bf. The breaking strength of the tile alone
is approximately 2500 lbf.
[0136] Results of a second test and the details of the testing
procedure are shown in Appendix E, which is attached hereto and
made a part of this disclosure. A porcelain tile that was 24 inches
wide, 24 inches long, and 20 mm thick was cut to be 12 inches wide
and 12 inches long. A 1/8-inch thick substrate 120a comprised of
Extren 500 series was cut to 12 inches by 12 inches and adhered to
one side of the porcelain tile. A technical data sheet for this
substrate 120a is shown in Appendix G, which is incorporated by
reference herein and made a part of this disclosure. Ten reinforced
tiles 120 were tested according to ASTM C648-04 (2014) "Standard
Test Method for Breaking Strength of Ceramic Tile" and exhibited an
average breaking strength of 4183 lbf, with the lowest being 1314
lbf and the highest being 6352 lbf. The breaking strength of the
tile alone is approximately 2500 lbf
[0137] Through testing, it has been found that the reinforced tile
120 using the 1/8-inch-thick substrate 120a may be desirable to
that using the 1/4-inch-thick substrate 120a. Generally, the
reinforced tile 120 using the 1/8-inch-thick substrate 120a is
lighter and less expensive than that using the 1/4-inch-thick
substrate 120a. Additionally, the reinforced tile 120 using the
1/8-inch-thick substrate120a provides a lower profile than that
using the 1/4-inch-thick substrate 120a.
[0138] These reinforced tiles 120 were also testing according to
ASTM C674-13 "Standard Test Methods for Flexural Properties of
Ceramic Whiteware Materials," which test procedures and results of
the ten reinforced tiles 120 are also shown in Appendix E.
Additionally, these reinforced tiles 120 were tested according to
ISO 10545-5 "Determination of Impact Resistance by Measurement of
Coefficient of Restitution," which test procedures and results of
the ten reinforced tiles 120 are also shown in Appendix E.
[0139] Results of a third test and the details of the testing
procedure are shown in Appendix F, which is attached hereto and
made a part of this disclosure. A porcelain tile that was 24 inches
wide, 24 inches long, and 20 mm thick was cut to be 12 inches wide
and 12 inches long. A woven FRP product that is marketed as Lamicor
Grade GP-9306 (sold by Liberty Pultrusion), a technical data sheet
for which is attached hereto and made a part hereof as Appendix B,
having a thickness of 1/8 was cut to 12 inches by 12 inches and
adhered to one side of the porcelain tile. Ten of these reinforced
tiles 120 were tested according to ASTM C648-04 (2014) "Standard
Test Method for Breaking Strength of Ceramic Tile" and exhibited an
average breaking strength of 5707 lbf, with the lowest being 4513
lbf and the highest being 6570 lbf The breaking strength of the
tile alone is approximately 2500 lbf.
[0140] These reinforced tiles 120 were also testing according to
ASTM C674-13 "Standard Test Methods for Flexural Properties of
Ceramic Whiteware Materials," which test procedures and results of
the ten reinforced tiles 120 are also shown in Appendix F.
[0141] Results of a fourth test and the details of the testing
procedure are shown in Appendix H, which is attached hereto and
made a part of this disclosure. A porcelain tile that was
approximately 60 cm wide, approximately 60 cm long, and
approximately 2 cm thick was adhered to a piece of fiberglass that
was approximately 24 inches wide, approximately 24 inches long, and
approximately 1/8 inch thick. A woven FRP product that is marketed
as Lamicor Grade GP-9306 (old by Liberty Pultrusion), a technical
data sheet for which is attached hereto and made a part hereof as
Appendix B was used as the substrate 120a. The porcelain tile with
fiberglass substrate 120a was then sent to a hydraulic press and
placed under pressure for complete adhesion and allowed to dry. A
CNC machine was used to remove excess substrate 120a, form a groove
24a on two parallel edges 24, and form one or more protrusions 24b
on the parallel edges 24 without grooves 24a. This reinforced tile
120 was cut to be approximately 12 inches wide and approximately 12
inches long. Five of these reinforced tiles 120 were tested
according to ASTM C674-13 (2018) "Standard Test Methods for
Flexural Properties of Ceramic Whiteware Materials," which test
procedures are described in Appendix H. The five reinformed tiles
120 tested exhibited an average Modulus of Rupture in pounds per
square inch (psi) of 7959.
[0142] The reinforced tiles 120 may be differently configured
depending on the specific application. As shown in FIGS. 24A-24C,
the edge of the substrate 120a may be proud, recessed, or flush
with respect to the edge of the tile without limitation unless
otherwise indicated in the following claims. Additionally, the
thickness of tile and substrate 120a can each vary depending at
least upon the combined strength and/or shatter resistance
necessary for application and are therefore in no way limit the
scope of the present disclosure unless otherwise indicated in the
following claims.
[0143] Although the best results for breaking strength and/or
shatter resistance of the reinforced tile 120 were achieved using
the woven FRP product shown in Appendix B, and testing has showed
that these reinforced tiles 120 exhibit desirable performance for
modulus of rupture (which could also be referred to flexural
strength per ASTM C674-13), frost cycle, and thermal shock, other
substrates 120a and/or composites may be used to create a
reinforced tile 120 without limitation unless otherwise indicated
in the following claims. The substrate 120a used for the reinforced
tile 120 having test results shown in Appendix F may be formed as a
plate that is woven (as opposed to a substrate 120a having all
strands parallel or approximately parallel), which woven
configuration may lead to a relative strength and/or shatter
resistance improvement in the substrate 120a plate and the
resulting reinforced tile 120. It is contemplated that if a FRP
substrate 120a is used, it may lead to increased strength and
shatter resistance in the resulting reinforced tile 120 if the
substrate 120a is woven or an irregular mat, such that individual
strands and/or components are positioned in various orientations
without limitation unless otherwise indicated in the following
claims. Generally, the substrate 120a may he adhered to the tile to
create a reinforced tile 120 using any suitable structure and/or
apparatus without limitation unless so indicated in the following
claims. It is contemplated that for some applications it may be
desirable to employ an adhesive that remains at least partially
flexible rather than becoming brittle upon curing. Such properties
may be required to pass certain freeze-thaw tests.
[0144] In one embodiment a two-part epoxy chemical adhesive may be
used to bind the substrate 120a to the tile. The two-part epoxy may
be comprised of a resin and hardener, which may be proportioned and
mixed by hand, mechanically, or an automated process. A desired
amount the resulting mixture may then be applied to the substrate
120a and/or tile by hand (e.g., spread with a trowel or putty
knife), mechanically (e.g., with a pneumatic spray device), of via
an automated process. It is contemplated that an automated process
may be used to automatically dispense a desired amount of mixed
adhesive and automatically apportion that adhesive over the surface
area of the substrate 120a or tile without limitation unless
otherwise indicated in the following claims.
[0145] After adhesive is placed on the substrate 120a or tile, the
substrate 120a may be joined with the tile. Mechanical force (e.g.,
presses, rollers, etc.) may be used to ensure evenness of the
adhesive, proper bonding, and a relatively even thickness of the
resulting reinforced tile 120. The adhesive may be allowed to dry
prior to transport and/or use. It is contemplated that such a
process at any and/or all points of construction may be temperature
and/or pressure controlled for quality control without limitation
unless otherwise indicated in the following claims. The reinforced
tiles 120 may be subjected to a machining or finishing process
(which may be done via a CNC machine) to ensure proper dimensions
and/or shape and enhance quality control.
[0146] One illustrative embodiment of a reinforced tile 120 shown
in FIGS. 25A & 25B, wherein FIG. 25A provides a perspective
view and FIG. 25B provides a side view, may include at least one
groove 24a formed therein on an edge 24 thereof. A second
illustrative embodiment of a reinforced tile 120 having grooves 24a
formed therein is shown in FIGS. 26A & 26B, wherein FIG. 26A is
a side view of a first edge 24 and FIG. 26B is a side view of a
second edge 24 that is perpendicular to the first edge 24.
Representative dimensions of various features are shown in FIGS.
26A & 26B, but those dimensions are for illustrative purposes
only and are in no way limiting to the scope of the reinforced tile
120 unless otherwise indicated in the following claims.
[0147] As shown in FIGS. 26A & 26B, for a reinforced tile 120
that is approximately 24 inches wide by approximately 24 inches
long by approximately 7/8 inches thick, the groove 24a may be 3/32
inches tall and the substrate 120a may be 7/64 inches thick
(wherein the thickness of the substrate 120a is in the same
dimension as the height of the groove 24a). The groove 24a may
extend inward from the edge 24 by approximately 13/64 inches (which
may be referred to as the depth of the groove 24a). Accordingly,
the height of the groove 24a may be between 5% and 25% of the
thickness of the tile and between 50% and 95% of the thickness of
the substrate 120a without limitation unless otherwise indicated in
the following claims. The height of the groove 24a may be between
20% and 80% of the depth thereof, and depth of the groove 24a may
be between 75% and 250% of the thickness of the substrate 120a.
Again, these dimensions are for illustrative purposes only and are
in no way limiting to the scope of the reinforced tile 120 unless
otherwise indicated in the following claims.
[0148] Either embodiment of the reinforced tile 120 may be
configured with a groove 24a along each of two parallel edges 24 as
previously described in detail above regarding a tile 20, or along
any edge 24. Opposite parallel edges 24 may be formed with one or
more protrusions 24b, also described in detail above regarding a
tile 20. Edges 24 having protrusions 24b thereon may also be formed
with a groove 24a without limitation unless otherwise indicated in
the following claims. Generally, the groove(s) 24a and/or
protrusions 24b may be configured, shaped, and/or dimensioned in
any manner as previously described herein, or may be differently
configured, shaped, and/or dimensioned without limitation unless
otherwise indicated in the following claims. It is contemplated
that the optimal configuration of the reinforced tile 120 and/or
grooves 24a therein may depend at least upon the application for
the reinforced tile 120.
[0149] In the illustrative embodiments of a reinforced tile 120,
the groove 24a may be machined in a reinforced tile 120
approximately along the interface between the tile 20 and substrate
120a such very little if any of the substrate 120a is removed to
create the groove 24a, and the groove 24a instead is formed by
removing only a portion of the tile 20 and/or a nominal portion of
the adhesive between the tile 20 and the substrate 120a as shown in
FIGS. 28A-29B. The substrate 120a may allow for the groove 24a to
be machined in an edge 24 of the reinforced tile 120 without
reducing the dimensions of the substrate 120a, thereby creating a
mechanism that is strong enough to not blow away, &laminate,
crack, crumble, make noise, and/or provide various other benefits
over the prior art because the entire thickness of the substrate
120a is positioned adjacent the rail 36 of the support structure 30
(or other corresponding component depending on the application of
the reinforced tile 120) without limitation unless otherwise
indicated in the following claims. Machining this type of groove
24a into a tile alone or prior art tiles with backing options
(e.g., galvanized metals) would not provide a continuous groove,
requisite strength, and/or complete adhesive coverage required to
meet various wind uplift strength standards.
[0150] Reinforced tiles 120 constructed in a manner as those
previously described with regards to Appendix H having grooves 24a
formed in at least two edges 24 thereof (such as those shown in
FIGS. 25A-26B) were subjected to wind uplift testing by PRI
Construction Materials Technologies, LLC based out of Tampa, Fla.
These tests were completed as described in the ANSI/FM Approvals
4474 (2004) Appendix B: Simulated Wind Uplift Pull Test Procedure.
The testing methodology arid results are shown in Appendix I, which
is attached hereto and made a part of this disclosure. As shown and
described in Appendix I, the method of failure of a reinforced tile
120 when tested in such a manner may be the substrate 120a
separating from the tile at the interface of the tile and substrate
120a without limitation unless otherwise indicated in the following
claims. The max passing load in pounds force for the illustrative
reinforced tile 120 tested in Appendix I was 1680.
[0151] A pedestal 50 and support structure 30, 30' engaged with the
pedestal 50 were subjected to evaluate the pedestal 50 and support
structure 30, 30' engaged therewith in accordance with ANSI/SPRI
ES-1 Wind Design Standard for Edge Systems Used in Low Slope
Roofing Systems, SPRI Test RE-2 Pull-Off Test for Edge flashings
(2003) and ANSI/SPRI/FM 4435/ES-1 Wind Design Standard for Edge
Systems Used with Low Slope Rooting Systems, RE-2 Pull-Off Test for
Edge flashings (2011). The testing methods and results are shown in
Appendix J, which is attached hereto and made a part of this
disclosure.
[0152] Another pedestal 50 and support structure 30, 30' engaged
with the pedestal 50 were subjected to evaluate the pedestal 50 and
support structure 30, 30' engaged therewith in accordance with
ANSI/SPRI ES-1 Wind Design Standard for Edge Systems Used in Low
Slope Roofing Systems, SPRI Test RE-2 Pull-Off Test for Edge
flashings (2003) and ANSI/SPIN/FM 4435/ES-1 Wind Design Standard Or
Edge Systems Used with Low Slope Roofing Systems, RE-2 Test Or Edge
flashings (2011). The testing methods and results are shown in
Appendix K, which is attached hereto and made a part of this
disclosure.
[0153] Reinforced tiles 120 such as those shown in FIGS. 25A-26B in
conjunction with a plurality of pedestals 50 and support structures
30, 30' engaged with the pedestals 50 were used to construct an
illustrative decking/roofing surface as disclosed in detail in
Appendix L, which is attached hereto and made a part of this
disclosure. The illustrative decking/roofing surface as subjected
to an environment sufficient to determine the simulated wind uplift
resistance for the illustrative decking/roofing surface in
accordance with UL 1897-04 Uplift Tests for Roof Covering Systems.
The testing methods and results are shown in detail in Appendix L.
The results of this testing, as shown in Appendix L, show that the
illustrative decking/roofing surface achieved a Class 90 rating per
UL 1897-04 testing procedure, and withstood a nominal static uplift
pressure of at least 90 pounds per square foot, a range of
oscillating pressure of at least 66 to 90 pounds per square foot,
and a maximum static uplift pressure of at least 105 pounds per
square foot. However, the scope of the present disclosure is not so
limited, and other embodiments of the reinforced tile 120, support
structures 30, 30', and/or pedestals 50 may have different results
according to the Classes found at
https://legacy-uploads.ul.com/wp-content/uploads/2014/04/ul_Roof-
ingWindResistance1.pdf without limitation unless otherwise
indicated in the following claims.
[0154] Another illustrative embodiment of a reinforced tile 120
wherein the substrate 120a may be comprised of a fiber reinforced
concrete (FRC) material is shown in FIGS. 27A & 27B. The
optimal FRC material may vary from one application of the
reinforced tile 120, and the specific FRC material is therefore in
no way limiting to the scope thereof unless otherwise indicated in
the following claims. Through testing Applicant has found that a
product marketed under the name "fibreC" by German company Rieder
Faserbeton-Elemente GmbH and/or Rieder Smart Elements GmbH, the
technical manual for which FRC material is available at
https://www.rieder.cc/wp-content/uploads/2017/07/fibreC-Technical-Manual.-
pdf, may be suitable for certain applications of the reinforced
tile 120 without limitation unless otherwise indicated in the
following claims.
[0155] In one embodiment, the fiberC material is about 90% sand and
cement with the remainder being fiberglass, pigments, and concrete
additives, and the product is made from cement-bonded fine concrete
reinforced with alkali-resistant fiberglass. Generally, such
material may be non-flammable and exhibit temperature stability up
to 350 C. The material may be generally weather-resistant, durable,
able withstand relatively heavy loads, exhibit high mechanical
stability, and are dimensionally stable.
[0156] Generally, this illustrative embodiment of a reinforced tile
120 may provide at least the benefits and advantages of those
previously described herein without limitation unless otherwise
indicated in the following claims. As shown, the illustrative
embodiment of a reinforced tile 120 having a substrate 120a
comprised of an FRC material may be engaged with a support system
30, 30' in a manner similar or identical to that previously
described for other embodiments of a reinforced tile 120 without
limitation unless otherwise indicated in the following claims. The
substrate 120a comprised of an FRC material may be adhered to
and/or engaged with the tile using any suitable method and/or
structure, including but not limited to chemical adhesives (e.g.,
glues, two-part epoxies, etc.), mechanical fasteners, and/or
combinations thereof without limitation unless otherwise indicated
in the following claims.
[0157] In the illustrative embodiment of a reinforced tile 120
shown in FIGS. 27A & 27B may have a groove 24a formed in the
substrate 120a. rather than the tile portion of the reinforced tile
120. It is contemplated that the groove 24a formed in the substrate
120a may be similar or identical to a groove 24a previously
described in detail that is formed in the tile without limitation
unless otherwise indicated in the following claims. Additionally, a
reinforced tile 120 with a substrate 120a comprised of an FRC
material may be formed with one or more protrusions 24b on one or
more edges of the substrate 120a and/or tile as previously
described above without limitation unless otherwise indicated in
the following claims.
[0158] In the illustrative embodiment shown in FIGS. 27A &.
27B, the substrate 120a may have an area and a shape approximately
the same as those of the tile, and the thickness of the substrate
120a may be approximately 0.25 to 0.75 inches for a tile having a
thickness of from approximately 0.65 to 0.90 inches without
limitation unless otherwise indicated in the following claims.
Accordingly, the percentage of the thickness of the overall
reinforced tile 120 that is attributable to the substrate 120a for
the illustrative embodiment of the reinforced tile 120 shown in
FIGS. 27A & 27B may be greater than that of other reinforced
tiles 120 without limitation unless otherwise indicated in the
following claims. For example, the percentage of the thickness of
the overall reinforced tile 120 that is attributable to the
substrate 120a for the illustrative embodiment of the reinforced
tile 120 shown in FIGS. 27A & 27B may be approximately between
20% and 65%, and more specifically may be approximately between 30%
and 45% without limitation unless otherwise indicated in the
following claims.
[0159] Reinforced tiles exhibit numerous advantages over the prior
art, which advantages include but are not limited to increased
breaking strength, which in turn may lead to numerous other
advantages including but not limited to: (1) elimination/mitigation
of shatter liability; (2) elimination/mitigation of liability of
glass-like edges when tiles shatter; (3) prior art broken tiles can
shatter and create shards that cause cuts and injuries, whereas
reinforced tiles 120, even if broken, are still contained and
bonded to a substrate 120a plate, which may prevent sharp edges and
separation of fragments; (4) provision of a longer warranty and
more durable product; (5) allowing raised use on pedestals without
voiding tile manufacturers warranties; (6) allowing safe use on
pedestals for the growing roof-deck market; (7) may be applied to
various tile manufacturer's products for use with various tile
products in a variety of thicknesses and sizes; (8) allowing for
heavier objects and loads to be placed on tiles without shatter
(e.g., furniture, planters, hot-tubs, outdoor kitchens, people,
etc.); (9) when prior art tiles shatter, sharp edges therefrom
penetrate waterproof membrane beneath, causes expensive and
extensive roof repairs; and, (10) may be used instead of unsightly
concrete pavers that have two- to three-year warranties, weigh
three to five times as much, are subject to stain and mold, and
require maintenance
[0160] From the preceding detailed description, it will be apparent
to those of ordinary skill in the art that the present disclosure
provides many benefits over the prior art. Some of those benefits
include, but are not limited to: (1) the ability to provide a deck
12, patio, roof, or other surface having tiles 20 and/or reinforced
tiles 120 without the need for grout and/or other sealer; (2) the
ability to provide a deck 12, patio, roof, or other surface that is
virtually maintenance free; (3) the ability to provide a deck 12,
patio, roof, or other surface that mitigates and/or eliminates
puddling even when the surface is level and/or nearly level; (4)
the ability to provide a more robust deck 12, patio, roof, or other
surface that is not affected by typical freeze/thaw cycles; (5) the
ability to allow a certain amount of relative movement between
tiles 20 and/or reinforced tiles 120, tiles 20 and/or reinforced
tiles 120 and support structures 30, tiles 20 and/or reinforced
tiles 120 and joists 14, and/or tiles 20 and/or reinforced tiles
120 and other structures without damaging the tiles 20 and/or
reinforced tiles 120; and, (6) the ability to suspend a tile
surface using properly configured pedestals 50 and thereby securing
each tile 20 and/or reinforced tiles 120 in one, two, and/or three
dimensions (which may properly secure each tile 20 and/or
reinforced tiles 120 and prevent and/or mitigate wind uplift).
[0161] Although the descriptions of the illustrative aspects of the
present disclosure have been quite specific, it is contemplated
that various modifications could be made without deviating from the
spirit and scope of the present disclosure. Accordingly, the scope
of the present disclosure is not limited by the description of the
illustrative aspects and/or corresponding figures unless so
indicated in the following claims.
[0162] The number, configuration, dimensions, geometries, and/or
relative locations of the various elements of the tile 20,
reinforced tiles 120, pedestal 50, spine 34, rail 36, and/or
support structure 30 will vary from one aspect of the present
disclosure to the next, as will the optimal configuration thereof.
Accordingly, the present disclosure is in no way limited by the
specific configurations, dimensions, and/or other constraints of
those elements unless so indicated in the following claims.
[0163] In the foregoing detailed description, various features are
grouped together in a single embodiment for purposes of
streamlining the disclosure. This method of disclosure is not to be
interpreted as reflecting an intention that the present disclosure
requires more features than are expressly recited in each claim.
Rather, as the following claims reflect, inventive aspects lie in
less than all features of a single foregoing disclosed embodiment.
Thus, the following claims are hereby incorporated into this
detailed description, with each claim standing on its own as a
separate embodiment.
[0164] The materials used to construct the tile and support system
10 and various elements and/or components thereof will vary
depending on the specific application thereof, but it is
contemplated that polymers, metals, metal alloys, natural
materials, stone, cement, ceramics, fibrous materials, and/or
combinations thereof may be especially useful for the tile and
support system 10 in some applications. Accordingly, the
above-referenced elements may be constructed of any material known
to those skilled in the art or later developed, which material is
appropriate for the specific application of the present disclosure
without departing from the spirit and scope of the present
disclosure unless so indicated in the following claims.
[0165] Having described the preferred embodiments of the various
methods and apparatuses, other features of the present disclosure
will undoubtedly occur to those versed in the art, as will numerous
modifications and alterations in the various aspects as illustrated
herein, all of which may be achieved without departing from the
spirit and scope of the present disclosure. Accordingly, the
methods and embodiments pictured and described herein are for
illustrative purposes only, and the scope of the present disclosure
extends to all method and/or structures for providing the various
benefits and/or features of the present disclosure unless so
indicated in the following claims. Furthermore, the methods and
embodiments pictured and described herein are no way limiting to
the scope of the present disclosure unless so stated in the
following claims.
[0166] Although several figures are drawn to accurate scale, any
dimensions provided herein are for illustrative purposes only and
in no way limit the scope of the present disclosure unless so
indicated in the following claims. It should be noted that the tile
and support structure 10, pedestal 50, spine 34, rail 36 and/or
components thereof are not limited to the specific embodiments
pictured and described herein, but are intended to apply to all
similar apparatuses and methods positioning and/or retaining
tile(s) 20 and/or reinforced tiles 120 and/or for increasing the
durability and/or strength of reinforced tiles 120. Modifications
and alterations from the described embodiments will occur to those
skilled in the art without departure from the spirit and scope of
the present disclosure.
[0167] Any of the various features, functionalities, aspects,
configurations, etc. for the tiles 20, reinforced tiles 120,
support structure 30, spine 34, rail 36, roof support structure
30', inner member 40 and/or pedestal 50, retaining element 60, 60',
and/or components of any of the foregoing may be used alone or in
combination with one another (depending on the compatibility of the
features) from one embodiment and/or aspect of the tile and support
system 10 to the next. Accordingly, an infinite number of
variations of the tile and support system. 10 exists. All of these
different combinations constitute various alternative aspects of
the tile and support system 10. The embodiments described herein
explain the best modes known for practicing the tile and support
system 10 and will enable others skilled in the art to utilize the
same. The claims are to be construed to include alternative
embodiments to the extent permitted by the prior art. Modifications
and/or substitutions of one feature for another in no wax limit the
scope of the tile and support system 10 and/or component thereof
unless so indicated in the following claims.
[0168] It is understood that the present disclosure extends to all
alternative combinations of one or more of the individual features
mentioned, evident from the text and/or drawings, and/or inherently
disclosed. All of these different combinations constitute various
alternative aspects of the present disclosure and/or components
thereof. The embodiments described herein explain the best modes
known for practicing the apparatuses, methods, and/or components
disclosed herein and will enable others skilled in the art to
utilize the same. The claims are to he construed to include
alternative embodiments to the extent permitted by the prior
art.
[0169] While the tiles 20, reinforced tiles 120, support structure
30, spine 34, rail 36, roof support structure 30', inner member 40
and/or pedestal 50, retaining element 60, 60', and/or components
thereof and/or methods of using same have been described in
connection with preferred aspects and specific examples, it is not
intended that the scope be limited to the particular embodiments
and/or aspects set forth, as the embodiments and/or aspects herein
are intended in all respects to be illustrative rather than
restrictive.
[0170] Unless otherwise expressly stated, it is in no way intended
that any method set forth herein be construed as requiring that its
steps be performed in a specific order. Accordingly, where a method
claim does not actually recite an order to be followed by its steps
or it is not otherwise specifically stated in the claims or
descriptions that the steps are to be limited to a specific order,
it is no way intended that an order be inferred, in any respect.
This holds for any possible non-express basis for interpretation,
including but not limited to: matters of logic with respect to
arrangement of steps or operational flow; plain meaning derived
from grammatical organization or punctuations the number or type of
embodiments described in the specification.
[0171] It should be noted that the present disclosure is not
limited to the specific embodiments pictured and described herein,
but are intended to apply to all similar apparatuses and methods
for arranging, securing, engaging tiles 20 and/or reinforced tiles
120, and/or otherwise providing any of the features and/or
advantages of any aspect of the present disclosure. Modifications
and alterations from the described embodiments will occur to those
skilled in the art without departure from the spirit and scope of
the present disclosure.
* * * * *
References