OUTDOOR FLOORING, DECK AND PATIO SURFACE SYSTEM AND METHOD
A system and method for providing an outdoor flooring such as a lightweight deck surface, employs a fiber reinforced polymer structural panel with plural grid openings therein. Connectors adapted to interlock adjacent panels to one another and to a base, also are adapted for receiving support column members therein for providing ground or base oriented surface or an elevated surface. A surfacing material, such as a quarried stone or tile, is attached to the top of the panel, providing a deck surface without requiring substantial structural support.
This application is a continuation-in-part of U.S. patent application Ser. No. 11/669,586 filed Mar. 31, 2007, which claims priority of U.S. provisional patent application 60/735,348, filed Mar. 31, 2006.
BACKGROUND OF THE INVENTIONThis invention relates to outdoor flooring, surfaces for decks, patios and the like, and more particularly, to a decking system and method for enabling use of surface materials that would ordinarily lack suitable structural features to accommodate deck or patio applications.
Stone walkway and step surfaces are frequently used at homes and businesses, as the appearance is attractive and enjoyed by many. Walkway and step stones are typically rather thick, to provide sufficient structural properties to support weight necessary in walkway and step use. As such, given the weight of stone, elevated deck surfaces such as for home decks, do not employ stone surfaces, as the weight of the stone requires substantially structural support beyond what is typically employed for deck construction.
SUMMARY OF THE INVENTIONIn accordance with the invention, a deck and patio surface system comprises a fiber reinforced structural panel employed as a substrate, a mounting fastener for enabling the panel to be secured to a deck, patio, or the like, and a surfacing material bonded or otherwise attached to the structural panel.
Accordingly, it is an object of the present invention to provide an improved deck system to enable use of stone surface in above-ground deck applications.
It is a further object of the present invention to provide an improved system for deck or patio applications to allow use of surface material not normally by itself having sufficient structural properties for such use.
It is yet another object of the present invention to provide an improved method for providing a deck surface.
Another object of the present invention is to provide a deck or patio system adapted for use over waterproofed living space without requiring penetration of the waterproof membrane.
It is still another object of the present invention to provide a system and method for providing a new surface over an existing damaged patio surface.
It is an additional object of the present invention to provide a system and method for providing a raised deck or surface for receiving tile, stone or other paver type surfacing.
The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements.
The system according to a preferred embodiment of the present invention comprises a composite deck surface having a structural panel, fastener elements to secure the structural panel to a deck base, and a surfacing material bonded to the structural panel.
Referring to
A surfacing material 22, which may comprise a cut stone having an aesthetically pleasing appearance, color and/or pattern, is suitably bonded to the structural panel, using a bonding material 24, for example. The surfacing material may also comprise tile, dry laid brick, concrete or stone pavers, for example.
The structural panel is suitably provided in sheets having dimensions of 4 foot by 8 foot, with a 1.5 inch square grid size, in the illustrated embodiment. The panel is suitably approximately 1 inch thick. The individual grid openings narrow somewhat from the top of the panel to the bottom, such that they are wider at the top face than at the bottom. In the particular embodiment, the opening is 1 5/16th inch at the top measured from interior edge to the opposite edge of an individual grid opening, but is 1¼th inch at the bottom face of the panel.
A suitable panel that is employed with the system and method may be a fiber reinforced general purpose polyester molded resin panel, although other materials may be used. The panel size is preferably 4 foot by 8 foot in the preferred embodiment, based on construction standards and practices, but may be otherwise re-sized to the desired dimensions, within a 1/16th inch tolerance, so as to provide a system that functions with 16 inch framing dimensions typically used in deck applications. The panel can be provided in other sizes than the illustrated example, chosen to have sufficient support while spanning the supporting elements supporting the panel. Preferably the panel is a pre-configured dimensional size suitable for compliance with customary building practices.
Referring now to
After the fastener is formed as in
In employing the system to provide a deck or patio surface, the installation steps illustrated in
Referring to
Referring now to
An edge trim 40 may now be applied to the peripheral edges of the assembled structural panel group, by cutting the trim to length and applying adhesive thereto (to the inside corners of the edge trim) and then mounting the edge trim to the edges of the panels (
The surface material 22 is now prepared and applied to the structural panel, illustrated in
In an alternative embodiment, the bonding material 24 is provided in the form of a sheet membrane 24′, such as an EPDM rubber or similar material, which is flexible and soft. The sheet is suitably 1/16th inch thick, of dimensions corresponding to those of the surfacing material 22, and is coated on both sides with a pressure sensitive contact adhesive. The sheet membrane 24′ is placed onto the surfacing material 22 and then the surfacing material is placed onto the structural panel 12. This alternative manner of adhering the material to the panel results in a flexible bond.
Accordingly, as system and method are provided whereby a deck surface of quarried stone is feasible. The use of the fiber reinforced polymer structural panels, the fasteners and the adhering of the stone tiles results in a lightweight high strength system weighing only 8 to 10 pounds per square foot in the preferred embodiment. The bonding of the surface material to the structural panel provides further strength to the overall system. As noted above, other surface materials may be employed, including but not limited to tile, brick, concrete and stone pavers.
Under an ASTM #E72-98 test, an exemplary system withstood 6282 lbs. of force with no failure, a maximum 1.47″ deflection and a maximum 0.35″ set deflection.
The preferred material for the surfacing material 22 is natural quarried stone, which includes slates, quartz and sandstone. All stones are suitably from deep cuts producing the highest quality and highest density stone for exterior applications.
In preferred embodiments, all stones have an ASTM #C121 Water Absorption of 0.10%-0.37%. and an ASTM #C1026 Freeze Thaw unaffected rating or a natural resistance to damage under these conditions. Generally all stones have an ASTM #1028 Coefficient of Friction equal to or greater than most wood or composite products, so as to not be overly slippery as a walking surface. In most cases sealing of the surface is not required due to the high density of this material. However, sealing can enhance the natural beauty if applied, but it is not required for long term durability.
Although the illustrated embodiment shows an outdoor flooring system use for a deck surface mounted to a wood frame, other uses are also possible. For example, the system and method can be employed as ground level patios, either as new construction or to cover a cracked or otherwise undesirable patio, providing positive drainage. Application to steps is also another use. Further, the system and method can be employed over waterproofed living spaces, for example, by placing the structural panels over the top of the waterproof deck on sleepers (horizontal structural member on or near the ground that support weight) as a level, floating deck, without penetrating the waterproof membrane.
Approximately centrally of the panel spanning from edge to edge is a cut line 50, defined by a double sidewall 58, 58′ between openings 14′ adjacent one another along the cut lines, with a central opening 60 defined therein. A solid portion 56 is provided across the cut line at regularly spaced intervals, the interval being the size of the spacing of the openings in the illustrated embodiment, The cut line 50 provides an easy to cut dividing line along the panel providing subdividable portions to easily cut the panel (or a portion thereof) into 2 parts or to cut out a standard size portion. Along the other direction of the panel, a pair of cut lines 52 and 54 are defined, suitably evenly spaced, to provide an easy to cut line defining 3 sub-dividable portions of the panel in that direction for sub-dividing the panel in to 3 subportions. In the illustrated embodiment, the cut lines enable easy cut lines with 2 foot and 16 inch spacings, which are typical joist spacings employed in deck construction, for example. Other dimension may be employed as desired to provide easy to cut lines along typically desired spacings.
There are 6 panels 12′ shown in
Referring to
Referring again to
Accordingly, with the herein described systems, gauged stone or tile may be employed in any outdoor living space (or indoor) in any climate and without the requirement of the use of traditional cement based mortars grouts or adhesives. Also, on grade pavers can be provided to surface the underlayment system with brick/concrete/stone pavers without the need for traditional sand beds.
The components of the systems described herein provide a strong yet light-weight underlayment assembly for a durable and secure exterior flooring surface, supplying strength, durability and creative flexibility.
In a particular embodiment, the outdoor floor system described herein weighs only 8-10 lbs. per square foot combined weight of the outdoor floor system underlayment and an average weight of a ¼″-½″ gauged stone or tile, which falls within the “10-15 lbs./sq′ of dead load” calculations for residential deck construction. Under these conditions the system can be placed over conventionally framed deck structures with joist spacing 16″-24″ O.C. A roof top terrace will also only need to be designed for standard load conditions. Paver deck applications will be 10-20 lbs./sq′ dead load and will require additional structural reinforcement and consultation with a licensed structural engineer.
The system can cover an existing cracked patio if the subgrade is stable. The finished patio can be installed as a level surface with positive drainage, and no cracks will migrate through the new finished stone surface. It can also be placed over any solid bearing surface. Each panel is supported by the interlocking connectors 62.
The high strength panel members have dimensional stability and minimal deflection under load conditions and require no additional surfacing material to achieve strength. This solid underlayment adds reinforcing strength to a stone/tile surface and bearing strength to a dry-laid paver surface.
The system further provides lateral strength or side-to-side stability, achieved in part by using adhesive to bond panel edges edge-to-edge.
In accordance with the above, a structural underlayment system used for outdoor floors is provided that can be placed over wood or metal joist framing or on a pedestal system. It supports natural gauged stone or tile, brick, concrete or stone pavers and can be used in place of other materials used for elevated decks or roof top terraces.
While plural embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the invention.
Claims
1. A flooring system, comprising: said panel member comprising:
- a structural panel member having length and width dimensions, adapted for mounting as a base framework;
- plural openings therein defined in a pattern in a portion of said panel member; and
- cutting guideline members for assisting in guiding cutting of said structural panel member into sub-panels, at least one of said sub-panels having a length or width dimension that is a pre-defined desired dimension.
2. The flooring system according to claim 1, wherein plural said cutting guideline members are provided to provided plural said pre-defined desired dimensions.
3. The flooring system according to claim 2, wherein said plural pre-defined desired dimensions comprise 24 inches and 16 inches.
4. The system according to claim 1, wherein said structural panel member comprises a fiber reinforced polymer panel.
5. The system according to claim 1, wherein said structural panel member is formed with plural openings therein.
6. The system according to claim 5, wherein said plural openings form a grid pattern.
7. The system according to claim 5, wherein ones of said plural openings are substantially rectangular in shape.
8. The system according to claim 5, wherein ones of said plural openings are substantially square in shape.
9. The system according to claim 5, comprising plural ones of said structural panel members and further comprising a connector member for connecting adjacent ones of said panel members to one another.
10. The system according to claim 9, wherein said connector member comprises engaging members for interacting with ones of said plural openings on said structural panels for providing engagement.
11. The system according to claim 1, further comprising a connector member for connecting said panel member to a base, wherein said connecting member comprises an engaging feature and said structural panel member comprises a corresponding engagement feature for interacting to provide engagement therebetween.
12. The system according to claim 11, further comprising a support column member, wherein said connector member further comprises an engaging feature for also engaging with said support column member for providing an elevated support for said panel member.
13. A flooring system, comprising:
- a structural panel member having length and width dimensions, adapted for mounting as a base framework;
- a connector for engaging with said structural panel member for securing said panel member to a base or to an adjacent other structural panel.
14. The system according to claim 13, wherein said connecting member comprises an engaging feature and said structural panel member comprises a corresponding engagement feature for interacting to provide engagement therebetween.
15. The system according to claim 13, wherein said base comprises a support column member, wherein said connector member further comprises an engaging feature for also engaging with said support column member for providing an elevated support for said panel member.
Type: Application
Filed: Mar 31, 2009
Publication Date: Mar 18, 2010
Inventors: David M. Busby (Beaverton, OR), Philip J. Busby (Beaverton, OR)
Application Number: 12/416,002
International Classification: E04B 5/02 (20060101);